Foam-in-bag systems and components thereof

ABSTRACT

A system includes a dispenser, first and second feed lines, and heating zones. The dispenser dispenses a first chemical precursor and a second chemical precursor. The first feed line permits flow of the first chemical precursor from a first source to the dispenser. The second feed line permits flow of the second chemical precursor from a second source to the dispenser. The heating zones are located along the first and second feed lines. The heating zones include a first heating zone located around a first portion of the first feed line and a second heating zone located around a first portion of the second feed line. The first heating zone and the second heating zone are independently controllable to independently control temperature around the first portion of the first feed line and temperature around the first portion of the second feed line.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of International ApplicationNo. PCT/US2019/018865, filed Feb. 21, 2019, which claims the benefit ofU.S. Provisional Application No. 62/634,262, filed Feb. 23, 2018, thecontents of each of which are hereby incorporated by reference in theirentirety.

BACKGROUND

The present disclosure is in the technical field of foam-in-bag systems.More particularly, the present disclosure describes embodiments offoam-in-bag systems, embodiments of components of foam-in-bag systems,embodiments of functions of foam-in-bag systems, and embodiments ofmethods associated with foam-in-bag systems.

SUMMARY

This summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This summary is not intended to identify key features ofthe claimed subject matter, nor is it intended to be used as an aid indetermining the scope of the claimed subject matter.

In one embodiment, a system is capable of dispensing a first chemicalprecursor and a second chemical precursor. The system includes adispenser, a first feed line, a second feed line, a first transfer pump,a first metering pump, a second transfer pump, and a second meteringpump. The dispenser is configured to dispense the first chemicalprecursor and the second chemical precursor. The first feed line isconfigured to feed the first chemical precursor from a source of thefirst chemical precursor to the dispenser. The second feed line isconfigured to feed the second chemical precursor from a source of thesecond chemical precursor to the dispenser. The first transfer pump islocated on the first feed line and configured to pump the first chemicalprecursor through the first feed line. The first metering pump locatedon the first feed line downstream of the first transfer pump andconfigured to pump the first chemical precursor through the first feedline. The second transfer pump located on the second feed line andconfigured to pump the second chemical precursor through the second feedline. The second metering pump located on the second feed linedownstream of the second transfer pump and configured to pump the secondchemical precursor through the second feed line.

In one example, the first and second metering pumps are configured tooperate based on an expected dispense amount of the first and secondchemical precursor by the dispenser. In another example, the firsttransfer pump is configured to operate based on a pressure differentialbetween an outlet of the first metering pump and an inlet of the firstmetering pump and the second transfer pump is configured to operatebased on a pressure differential between an outlet of the secondmetering pump and an inlet of the second metering pump. In anotherexample, the system further includes a first input pressure transducerconfigured to measure an inlet pressure in the first feed line upstreamof the first metering pump and a first output pressure transducerconfigured to measure an outlet pressure in the first feed linedownstream of the first metering pump, where the pressure differentialbetween the outlet of the first metering pump and the inlet of the firstmetering pump is determined based on the inlet pressure measured by thefirst input pressure transducer and the outlet pressure measured by thefirst output pressure transducer. In another example, the system furtherincludes a second input pressure transducer configured to measure aninlet pressure in the second feed line upstream of the second meteringpump and a second output pressure transducer configured to measure anoutlet pressure in the second feed line downstream of the secondmetering pump, where the pressure differential between the outlet of thesecond metering pump and the inlet of the second metering pump isdetermined based on the inlet pressure measured by the second inputpressure transducer and the outlet pressure measured by the secondoutput pressure transducer.

In another example, a first hose is located between the first transferpump and the first metering pump, the first feed line passes through thefirst hose, a second hose is located between the second transfer pumpand the second metering pump, and the second feed line passes throughthe second hose. In another example, each of the first and second hoseshas a length between about 1 foot and about 100 feet.

In another example, the system further includes a first dispensermanifold located on the first feed line downstream of the first meteringpump, where the first dispenser manifold includes a first input blockthrough which the first feed line passes and the first input blockincludes a first heating element, and a second dispenser manifoldlocated on the second feed line downstream of the second metering pump,where the second dispenser manifold includes a second input blockthrough which the second feed line passes and the second input blockincludes a second heating element. In another example, the systemfurther includes a first hose located between the first metering pumpand the first dispenser manifold, where the first feed line passesthrough the first hose and the first hose includes a third heatingelement, and a second hose located between the second metering pump andthe second dispenser manifold, where the second feed line passes throughthe second hose and the second hose includes a fourth heating element.In another example, the first heating element is in direct contact withthe first input block, the second heating element is in direct contactwith the second input block, the third heating element is in directcontact with the first chemical precursor in the first feed line, andthe fourth heating element is in direct contact with the second chemicalprecursor in the second feed line. In another example, the systemfurther includes a first manual shutoff valve located on the first feedline between the first dispenser manifold and the dispenser, where thefirst manual shutoff valve is capable of being closed to prevent flow ofthe first chemical precursor to the dispenser, and a second manualshutoff valve located on the second feed line between the seconddispenser manifold and the dispenser, where the second manual shutoffvalve is capable of being closed to prevent flow of the second chemicalprecursor to the dispenser.

In another example, the system further includes a first check valvelocated in the first feed line downstream of the first transfer pump,where the first check valve is configured to permit flow of the firstchemical precursor substantially only downstream in the first feed line,and a second check valve located in the second feed line downstream ofthe second transfer pump, where the second check valve is configured topermit flow of the second chemical precursor substantially onlydownstream in the second feed line. In another example, the systemfurther includes a first return line fluidly coupling the source of thefirst chemical precursor and the first feed line at a location betweenthe first transfer pump and the first metering pump and a second returnline fluidly coupling the source of the second chemical precursor andthe second feed line at a location between the second transfer pump andthe second metering pump. In another example, the first return lineincludes a first bleed valve and a first prime valve arranged inparallel on the first return line, where the first bleed valve and thefirst prime valve are capable of being selectively and independentlyopened and closed, and the second return line includes a second bleedvalve and a second prime valve arranged in parallel on the second returnline, where the second bleed valve and the second prime valve arecapable of being selectively and independently opened and closed. Inanother example, the first and second bleed valves are configured to beopen when the first and second bleed valves are unpowered and the firstand second prime valves are configured to be closed when the first andsecond prime valves are unpowered. In another example, at least one ofthe first transfer pump, the second transfer pump, the first meteringpump, and the second metering pump is a gerotor pump.

In another embodiment, a system includes a dip tube, a feed line, and acheck valve. The dip tube is configured to be inserted into through anopening in a source of chemical precursor and into the chemicalprecursor in the source. A portion of the feed line is located in thedip tube, the feed line passes out of the dip tube, and the chemicalprecursor is capable of flowing out of the source through the feed linein a downstream direction. The check valve is located in the portion ofthe feed line in the dip tube, where the check valve is configured topermit the chemical precursor to pass substantially only in thedownstream direction. The feed line is configured to be coupled to atransfer pump that is configured to draw the chemical precursor out ofthe source through the portion of the feed line in the dip tube.

In one example, the system further includes a filter located in theportion of the feed line in the dip tube, the filter is configured tofilter debris from the chemical precursor. In another example, thefilter is attached to an inside diameter of the feed line along amajority of a length of the dip tube. In another example, the systemfurther includes a transfer pump system that includes the transfer pump,where the feed line passes through the transfer pump system. In anotherexample, the system further includes a return line, where a portion ofthe return line is located in the dip tube, the feed line passes out ofthe dip tube to the transfer pump system, and the return line is influid communication with the feed line at a location downstream of thetransfer pump.

In another example, the system further includes a bleed valve and aprime valve located in parallel on the return line. In another example,the bleed valve is configured to be open when the bleed valve isunpowered and the prime valve is configured to be closed when the primevalve is unpowered. In another example, the system further includes acheck valve located in the feed line between the transfer pump and thelocation at which the return line is in fluid communication with thefeed line downstream of the transfer pump. In another example, thesystem further includes at least one hose coupled to the dip tube andcoupled to the transfer pump system, where the feed line and the returnline pass through the at least one hose. In another example, the systemfurther includes a pressure transducer configured to measure pressure inthe feed line upstream of the transfer pump, where the pressuretransducer is located outside of the source of the chemical precursor.In another example, the pressure transducer is located inside thetransfer pump system. In another example, the pressure measurement ofthe pressure transducer is indicative of a level of the chemicalprecursor in the source of the chemical precursor. In another example,the pressure measurement of the pressure transducer is indicative of ablockage in the feed line. In another example, the pressure measurementis indicative that cavitation is possible in the feed line. In anotherexample, the system further includes a temperature sensor configured tomeasure temperature in the feed line upstream of the transfer pump,where the temperature sensor is located outside of the source of thechemical precursor, and where the temperature measurement is furtherindicative that cavitation is possible in the feed line.

In another embodiment, a system includes a dispenser, a first feed line,a second feed line, and a plurality of heating zones. The dispenser isconfigured to dispense a first chemical precursor and a second chemicalprecursor. The first feed line is configured to permit flow of the firstchemical precursor from a first source to the dispenser. The second feedline configured to permit flow of the second chemical precursor from asecond source to the dispenser. The plurality of heating zones arelocated along the first and second feed lines, where the plurality ofheating zones includes a first heating zone located around a firstportion of the first feed line passes and a second heating zone locatedaround a first portion of the second feed line. The first heating zoneand the second heating zone are independently controllable toindependently control temperature around the first portion of the firstfeed line that passes through the first heating zone and temperaturearound the first portion of the second feed line that passes through thesecond heating zone.

In one example, the plurality of heating zones includes a third heatingzone located around a second portion of the first feed line and a secondportion of the second feed line, where the third heating zone iscontrollable independently of the first and second heating zones. Inanother example, the second portion of the first feed line is downstreamfrom the first portion of the first feed line and the second portion ofthe second feed line is downstream from the first portion of the secondfeed line. In another example, the dispenser is located in the thirdheating zone. In another example, each of the heating zones includes aheating element configured to heat at least one of the first chemicalprecursor, the second chemical precursor, a block through which thefirst feed line passes, or a block through which the second feed linepasses. In another example, each of the heating zones further includes atemperature sensor configured to measure a temperature of the at leastone of the first chemical precursor, the second chemical precursor, theblock through which the first feed line passes, or the block throughwhich the second feed line passes. In another example, each of theheating zones further includes a controller configured to control theheating element based on indications of the measured temperaturegenerated by the temperature sensor. In another example, the controlleris configured to control the heating element by alternating, based onthe indications of the measured temperature generated by the temperaturesensor, between causing the heating element to be powered and causingthe heating element to be unpowered.

In another example, the system further includes a first dispensermanifold including a first input block, where the first input block isthe first heating zone and the first portion of the first feed linepasses through the first input block, and a second dispenser manifoldincluding a second input block, where the second input block is thesecond heating zone and the first portion of the second feed line passesthrough the second input block. In another example, the first dispensermanifold further includes a first output block, where the first outputblock is in a third heating zone through which a second portion of thefirst feed line passes, and the second dispenser manifold furtherincludes a second output block, where the second output block is in afourth heating zone through which a second portion of the second feedline passes. In another example, the first input block includes a firstheating element configured to heat the first input block, a firsttemperature sensor configured to measure a temperature of the firstinput block, and a first controller configured to control operation ofthe first heating element based on the measured temperature from thefirst temperature sensor. In another example, the second input blockincludes a second heating element configured to heat the second inputblock, a second temperature sensor configured to measure a temperatureof the second input block, and a second controller configured to controloperation of the second heating element based on the measuredtemperature from the second temperature sensor. In another example, thefirst output block includes a third heating element configured to heatthe first output block, a third temperature sensor configured to measurea temperature of the first output block, and a third controllerconfigured to control operation of the third heating element based onthe measured temperature from the third temperature sensor. In anotherexample, the second output block includes a fourth heating elementconfigured to heat the second output block, a fourth temperature sensorconfigured to measure a temperature of the second output block, and afourth controller configured to control operation of the fourth heatingelement based on the measured temperature from the fourth temperaturesensor. In another example, the system further includes a mixingcartridge manifold in the dispenser, where a fifth heating zone is inthe mixing cartridge manifold, and where a third portion of the firstfeed line and a third portion of the second input line pass through thefifth heating zone in the mixing cartridge manifold. In another example,the dispenser includes a fifth heating element configured to heat themixing cartridge manifold, a fifth temperature sensor configured tomeasure a temperature of the mixing cartridge manifold, and a fifthcontroller configured to control operation of the fifth heating elementbased on the measured temperature from the fifth temperature sensor. Inanother example, the system further includes a first hose coupled to afirst input of the first dispenser manifold, where a fourth portion ofthe first feed line passes through the first hose and where the firsthose includes a sixth heating element configured to heat the firstchemical precursor passing through the fourth portion of the first feedline, and a second hose coupled to a second input of the seconddispenser manifold, where a fourth portion of the second feed linepasses through the second hose and where the second hose includes aseventh heating element configured to heat the second chemical precursorpassing through the fourth portion of the second feed line. In anotherexample, the system further includes a sixth temperature sensorconfigured to measure a temperature of the first chemical precursorpassing through the fourth portion of the first feed line and a sixthcontroller configured to control operation of the sixth heating elementbased on the measured temperature from the sixth temperature sensor. Inanother example, the first output block further includes a secondaryline configure to permit flow of a cleaning solution to the dispenserand the secondary line passes through the third heating zone.

In another embodiment, a system is capable of opening and closing amixing manifold, where the mixing manifold includes a valving rod, themixing manifold is open when the valving rod is retracted, and themixing manifold is closed when the valving rod is extended. The systemIncludes a drive motor, a cam plate, and a valving rod. The drive motoris configured to selectively impart movement in a first direction and ina second direction. The cam plate is coupled to the drive motor suchthat the movement imparted by the drive motor in the first directioncauses a linear movement of the cam plate in a third direction andmovement imparted by the drive motor in the second direction causes alinear movement of the cam plate in a fourth direction. The valving rodconnector is engaged with the cam plate such that linear movement of thecam plate in the third direction causes linear movement of the valvingrod connector in a fifth direction and linear movement of the cam platein the fourth direction causes linear movement of the valving rodconnector in a sixth direction. The valving rod connector is configuredto be coupled to the valving rod such that linear movement of thevalving rod connector in the fifth direction causes the valving rod tobe retracted to open the mixing manifold and linear movement of thevalving rod connector in the sixth direction causes the valving rod tobe extended to close the mixing manifold.

In one example, the third and fourth directions are opposite of andparallel to each other, and the fifth and sixth directions are oppositeof and parallel to each other. In another example, the third and fourthdirections are substantially perpendicular to the fifth and sixthdirections. In another example, the first and second directions arerotational directions that are opposite of each other. In anotherexample, the system includes the mixing manifold. In another example,the mixing manifold includes at least two inlets and a mixing chamberand the two inlets are configured to permit flow of two chemicalprecursors into the mixing chamber. In another example, the mixingmanifold further includes an outlet configured to permit flow of thechemical precursors out of the mixing chamber. In another example, thechemical precursors are configured to begin to react to form urethanefoam in response to mixing in the mixing chamber, and the flow of thechemical precursors out of the mixing chamber includes at least some ofthe urethane foam formed in the mixing chamber. In another example, whenthe mixing manifold is closed, the valving rod is extended through themixing chamber and the outlet, and, when the mixing manifold is closed,the valving rod is retracted back from the outlet and the mixingchamber. In another example, the drive motor is configured to impartsufficient driving force when extracting or retracting the valving rodthrough the mixing chamber to overcome an adhesion force between thevalving rod and the mixing chamber due to remnants of the urethane foamin the mixing chamber.

In another example, the system further includes a drive couplingassembly coupled to the drive motor and to the cam plate, where thedrive coupling assembly is configured to convert rotational motion ofthe drive motor into linear motion of the cam plate. In another example,the drive coupling assembly includes (1) a drive screw coupled to ashaft of the drive motor, where the drive screw is configured to rotatein response to rotation of the shaft of the drive motor, (2) a nutconfigured to engage with the drive screw, where the nut is configurednot to rotate when the drive screw rotates such that the nut moveslinearly when the drive screw rotates, and (3) a nut extender coupled tothe nut and coupled to the cam plate, where the nut extender translateslinear movements of the nut to linear movements of the cam plate. Inanother example, the system further includes a plurality of rollersconfigured to support and to guide the cam plate as the cam plate moveslinearly in the third and fourth directions. In another example, atleast one of the rollers is a V-shaped roller, at least one surface ofthe cam plate is a grooved surface, and the V-shaped roller isconfigured to engage the grooved surface.

In another embodiment, a system is capable of holding a roll of film,where the roll includes a core with film wound around the core and thecore has an inner surface. The system includes a rod, a proximal wing,and a distal wing. The rod has an outer diameter that is smaller than aninner diameter of the core. The proximal wing is located on the rod andconfigured to rotate about the rod. The proximal wing includes contactsurfaces configured to contact diametrically-opposed locations on aproximal side of the inner surface of the core and non-contact surfacesthat span between the contact surfaces of the proximal wing. Thenon-contact surfaces of the proximal wing are configured to not contactthe core if the core has a cylindrical shape. The distal wing is locatedon the rod and configured to rotate about the rod. The distal wingincludes contact surfaces configured to contact diametrically-opposedlocations on a distal side of the inner surface of the core andnon-contact surfaces that span between the contact surfaces of thedistal wing. The non-contact surfaces of the distal wing are configuredto not contact the core if the core has a cylindrical shape. The distalwing is capable of rotating around the rod independently of the proximalwing.

In one example, at least one of the contact surfaces of the proximalwing includes an engagement device configured to engage the innersurface of the core and to deter rotation of the core with respect tothe at least one of the contact surfaces of the proximal wing. Inanother example, the engagement device is biased outwardly from an axisof the rod by a biasing mechanism. In another example, the proximal wingincludes a pin configured to limit how far the biasing mechanisms canmove the engagement device away from the axis of the rod. In anotherexample, the proximal wing is operatively coupled to a motor configuredto rotate the proximal wing about the rod. In another example, thesystem further includes a proximal ring clamp releasably clampable tothe rod and configured to prevent the proximal wing from sliding towarda distal end of the rod and to keep the proximal wing operativelycoupled to the motor. In another example, the system further includes aroll guide configured to contact a proximal end of the core and to guidethe core towards axial alignment with the proximal wing as the roll isloaded onto the system from the distal end of the rod toward theproximal wing.

In another example, the system further includes a distal ring clampreleasably clampable to the rod and configured to prevent the distalwing from sliding toward a proximal end of the rod. In another example,the system further includes an end cap releasably coupled to a distalend of the rod, where the end cap is configured to prevent the distalwing from unintentionally sliding off the distal end of the rod. Inanother example, the system further includes a releasable clip locatedon one of the contact surfaces of the distal wing such that, when theroll is loaded on the system, the releasable clip is configured tocontact a distal end of the roll to deter axial movement of the rolltowards the distal end of the rod.

In another embodiment, a foam-in-bag system includes a spindle system, afirst drive roller assembly, a second drive roller assembly, a first niproller assembly, and a second nip roller assembly. The spindle system iscapable of holding a roll of film, where the spindle system has a firstwing and a second wing rotatably mounted on a rod and where the firstand second wings are configured to support first and second ends of theroll of film. Each of the first and second drive roller assemblyincludes a driven roller mounted on a drive shaft and configured to bedriven by rotation of the drive shaft. Each of the first and second niproller assemblies includes a nip roller configured to back one of thedriven rollers such that the film can pass between the driven rollersand the nip rollers and be fed when the driven rollers are driven.Transverse positions of the first wing, the first drive roller assembly,and the first nip roller assembly are configured to remain in aparticular transverse location regardless of a width of the roll offilm. Transverse positions of the second wing, the second drive rollerassembly, and the second nip roller assembly are configured to bechanged based on the width of the roll of film.

In one example, the foam-in-bag system further includes a dispenserconfigured to dispense chemical precursors into a bag formed from thefilm. In another example, the dispenser has a transverse location thatis independent of the transverse positions of the second wing, thesecond drive roller assembly, and the second nip roller assembly. Inanother example, the dispenser is configured to have a transverselocation based on at least one of a midway point between the first andsecond wings, a midway point between the first and second drive rollerassemblies, or a midway point between the first and second nip rollerassemblies. In another example, the foam-in-bag system further includesa sensor configured to generate an indication of a transverse positionof at least one of the second wing, the second drive roller assembly,and the second nip roller assembly. In another example, the foam-in-bagsystem further includes a controller configured to adjust the transverselocation of the dispenser based on the indication of the transverseposition generated by the sensor. In another example, the foam-in-bagsystem further includes a controller configured to adjust an amount ofthe chemical precursors dispensed by the dispenser based on theindication of the transverse position generated by the sensor. Inanother example, a user is capable of adjusting the transverse positionsof the second wing, the second drive roller assembly, and the second niproller assembly by hand without the use of tools. In another example,the first and second nip roller assemblies are located on a front coverof the foam-in-bag system, the front cover is configured to be closedduring ordinary operation and to be open during servicing of thefoam-in-bag system. In another example, the second nip roller assemblyincludes a clamping mechanism, and the clamping mechanism is configuredto be selectively clamped to the second drive roller assembly when thefront cover is closed.

In another embodiment, a longitudinal sealer includes a housingconfigured to be installed in a foam-in-bag system, an arm movablycoupled to the housing, and a heating element having a leading edgeexposed through an exterior surface of the arm. A position of the armwith respect to the housing is controllable so that the arm is movablebetween a first location where the leading edge of the heating elementis not in contact with a film in a film path of the foam-in-bag systemand a second location where the leading edge of the heating element isin contact with the film in the film path of the foam-in-bag system.

In one example, a longitudinal sealer further includes a temperaturesensor configured to generate one or more signals indicative of one ormore temperatures of the heating element. In another example, thetemperature sensor includes a first resistance temperature detectorlocated on an exterior surface on the heating element. In anotherexample, the temperature sensor further includes a second resistancetemperature detector embedded within the heating element. In anotherexample, when the housing is installed in the foam-in-bag system, thelongitudinal sealer is configured to be communicatively coupled to acontroller of the foam-in-bag system. In another example, thelongitudinal sealer is configured to send the one or more signalsgenerated by the temperature sensor to the controller, and thecontroller is configured to control a temperature of the heating elementbased on the one or more signals. In another example, the controller isconfigured to control the temperature of the heating element within arange of any one of 1° C., 2° C., or 5° C. of a target temperature. Inanother example, the controller is configured to control the position ofthe arm with respect to the housing. In another example, the foam-in-bagsystem includes an actuator configured to engage the longitudinal sealerto move the arm, and the controller is configured to control theposition of the arm with respect to the housing by controlling theactuator. In another example, the actuator is configured to engage aplunger of the longitudinal sealer, and the plunger is configured tocontact the arm to cause the arm to rotate in a first rotationaldirection. In another example, the housing further includes a biasingelement configured to bias the arm in a second rotational directionopposite the first rotational direction, whereby the biasing elementbiases the arm in the second rotational direction unless the plungerexerts a force on the arm so that a torque on the arm by the plungerovercomes a torque on the arm by the biasing element to cause the arm torotate in the first rotational direction.

In another example, the housing is configured to be installed in andremoved from the foam-in-bag system manually without the use of tools.In another example, the housing includes a slot configured to be slidinto a bracket of the foam-in-bag system. In another example, the slotincludes a bore, the bracket includes a spring-loaded pin, and the boreis configured to receive a first end of the spring-loaded pin. Inanother example, a second end of the spring-loaded pin includes a handleconfigured to permit a user to grasp the spring-loaded pin and pull thefirst end of the spring-loaded pin out of the bore.

In another embodiment, a system is capable of cutting and sealing film.The system includes a jaw assembly and a backing jaw. The jaw assemblyincludes a bar having a lateral surface, a first heating element, asecond heating element, and a third heating element. The first, second,and third heating elements are arranged across the lateral surface ofthe bar substantially parallel to each other and spaced out from eachother in a longitudinal direction. The backing jaw has a lateral side.The jaw assembly and the backing jaw are arranged such that the lateralside of the jaw assembly is substantially aligned with the lateral sideof the backing jaw. At least one of the jaw assembly and the backing jawis capable of moving with respect to the other of the jaw assembly andthe backing jaw so that the jaw assembly and the backing jaw arerespectively positionable between a first position where the lateralside of the jaw assembly is withdrawn from the lateral side of thebacking jaw and a second position where the lateral side of the jawassembly abuts the lateral side of the backing jaw.

In one example, when a film is located between the lateral sides of thejaw assembly and the backing jaw and the jaw assembly and the backingjaw are in the second position, the first and third heating elements areconfigured to form transverse seals in the film and the second heatingelement is configured to make a transverse cut in the film. In anotherexample, the system further includes a controller configured to controltemperatures of the first and third heating elements based on one ormore predetermined seal characteristics of the transverse seals formedby the first and third heating elements and to control a temperature ofthe second heating element based on one or more predetermined cutcharacteristics of the transverse cut made by the second heatingelement. In another example, the system further includes a movementmechanism configured to move the jaw assembly between the first andsecond positions. In another example, the system further includes atoggle having a first end coupled to a driving mechanism of the movementmechanism and a second end rotatably coupled to the bar of the jawassembly. In another example, the driving mechanism is configured tocause linear motion of the first end of the toggle in a transversedirection, where the toggle is arranged such that the linear motion ofthe first end of the toggle in the transverse direction causes linearmotion of the second end of the toggle in a lateral direction, and wherethe linear motion of the second end of the toggle in the lateraldirection causes linear motion of the bar in the lateral direction. Inanother example, the system further includes the jaw assembly furtherincludes lateral guides on either transverse side of the bar, where thelateral guides are arranged to properly guide movement of the bar in thelateral direction. In another example, the first end of the toggleincludes a roller configured to move within a slot, and the slot is in afixed position with respect to the movement mechanism.

In another example, the system further includes a low-adhesion mechanismhaving a low-adhesion material that is arranged to be wrapped around thelateral side of the bar. In another example, the low-adhesion mechanismfurther includes a first connector configured to be releasably coupledto one of a top of the bar and a bottom of the bar and a secondconnector configured to be releasably coupled to the other of the top ofthe bar and the bottom of the bar, where the low-adhesion material spansbetween the first and second connectors. In another example, the firstconnector includes a distal end configured to be secured to a protrusionand/or a groove on the one of the top of the bar and the bottom of thebar, and the second connector includes a distal end configured to besnapped on to a mating snap-in connector on the other of the top of thebar and the bottom of the bar. In another example, the low-adhesionmaterial between the first and second connectors is a flexible material.In another example, the low-adhesion friction material is wrapped aroundthe lateral side of the bar so that the first and third heating elementsare covered by the low-adhesion friction material and the second heatingelement is not covered by the low-adhesion friction material. In anotherexample, the system further includes a first set of posts configured tohold the first heating element across the lateral side of the bar, asecond set of posts configured to hold the second heating element acrossthe lateral side of the bar, and a third set of posts configured to holdthe third heating element across the lateral side of the bar, where thefirst, second, and third sets of posts are quick-release elements thatare configured to be disengaged from the bar by a user by hand withoutthe use of tools.

In another embodiment, a method of using a foam-in-bag system to formbags of foam includes forming a bottom transverse seal near a firsttransverse cut in two plies of film, where the first transverse cutforms a bottom of a bag made from the film. The method further includesforming at least one longitudinal seal near at least one longitudinalside of the two plies of the film, where the at least one longitudinalseal forming at least one side of the bag. The method further includesclosing pinching jaws across a transverse width of the bag and above thebottom transverse seal of the bag with the two plies of film in betweenthe pinching jaws. The method further includes, while pinching jaws areclosed, dispensing foaming chemical precursors between the two plies ofthe film, where the closed pinching jaws deter the dispensed foamingchemical precursors from flowing to the bottom transverse seal. Themethod further includes, after at least a portion of the dispensedfoaming chemical precursors have reacted to form foam, opening thepinching jaws so that the film with the dispensed foaming chemicalprecursors inside is capable of passing through the open pinching jaws.

In one example, the method further includes, after opening the pinchingjaws, feeding the film so that the portion of the film with thedispensed foaming chemical precursors passes below the open pinchingjaws. In another example, the method further includes, after opening thepinching jaws, forming a top transverse seal in the two plies of film.

In another example, the method further includes making a secondtransverse cut in the two plies of film, the second transverse cutforming a top of the bag and separating the bag from the film. Inanother example, the second transverse cut also forms a bottom of asubsequent bag made from the film. In another example, the methodfurther includes forming a bottom transverse seal near the secondtransverse cut; continuing forming the at least one longitudinal sealnear the at least one longitudinal side of the two plies of the film,where the at least one longitudinal seal forms at least one side of thesubsequent bag; closing pinching jaws across a transverse width of thesubsequent bag and above the bottom transverse seal of the subsequentbag with the two plies of film in between the pinching jaws; whilepinching jaws are closed, dispensing foaming chemical precursors betweenthe two plies of the film, the closed pinching jaws deter the dispensedfoaming chemical precursors from flowing to the bottom transverse sealof the subsequent bag; and, after at least a portion of the dispensedfoaming chemical precursors have reacted to form foam, opening thepinching jaws so that the film with the dispensed foaming chemicalprecursors inside is capable of passing through the open pinching jaws.In another example, closing the pinching jaws includes closing thepinching jaws at a distance away from the bottom transverse seal basedon an expected height of the bag. In another example, the distance awayfrom the pinching jaws is approximately half of the expected height ofthe bag. In another example, the distance away from the pinching jaws isapproximately half of the expected height of the bag less an offset. Inanother example, the offset is based on an amount of expected foamformed from the dispensed foaming chemical precursors before opening thepinching jaws.

In another example, a first pinching jaw of the pinching jaws has acircular cross-section, and a second pinching jaw of the pinching jawshas an L-shaped cross-section. In another example, the pinching jawsinclude first and second pinching jaws that are rotationally coupled toeach other so that rotation of the first pinching jaw in one rotationaldirection causes rotation of the second pinching jaw in an oppositerotational direction. In another example, at least one of the first andsecond pinching jaws is operatively coupled to a motor. In anotherexample, the method further includes controlling operation of the motorto cause the closing and the opening of the pinching jaws. In anotherexample, at least one of the first and second pinching jaws is coupledto a biasing element, where the biasing element is arranged to bias thefirst and second pinching jaws to an open position when the motor isunpowered.

In another embodiment, a system is capable of detecting foaming chemicalprecursors in a foam-in-bag system. The foam-in-bag system configured todispense the foaming chemical precursors between two plies of film intoa bag formed from the two plies of film. The system includes a source, adetector, and a controller. The source is positioned on a first side ofthe two plies of film and configured to emit electromagnetic energytoward the two plies of film. At least a portion of the emittedelectromagnetic energy is within a range of wavelengths. The detector ispositioned on a second side of the two plies of film and arranged todetect electromagnetic energy propagating away from the two plies offilm. The detector is configured to detect electromagnetic energy withinthe range of wavelengths and generate signals indicative of intensity ofdetected electromagnetic energy within the range of wavelengths. Thecontroller is configured to receive the signals indicative of thedetected electromagnetic energy within the range of wavelengths and tocontrol operation of the foam-in-bag system based at least in part onthe signals indicative of the detected electromagnetic energy within therange of wavelengths. The film is transmissive of electromagnetic energyin the range of wavelengths. At least one of the foaming chemicalprecursors or foam formed from a reaction of the foaming chemicalprecursors is opaque to electromagnetic energy in the range ofwavelengths.

In one example, the range of wavelengths is within a range of infraredelectromagnetic energy, the film is transmissive of electromagneticenergy in the range of infrared electromagnetic energy, and the at leastone of the foaming chemical precursors or foam formed from a reaction ofthe foaming chemical precursors is opaque to electromagnetic energy inthe range of infrared electromagnetic energy. In another example, thesignals indicative of the detected electromagnetic energy within therange of wavelengths are indicative of a distance between a dispenser inthe foam-in-bag system and the foam formed from a reaction of thefoaming chemical precursors.

In another example, the signals indicative of the detectedelectromagnetic energy within the range of wavelengths are indicative ofa geometry of a stream of the foaming chemical precursors beingdispensed by the dispenser.

In another example, the source includes a plurality of distinct sourcesof the electromagnetic energy. In another example, the plurality ofdistinct sources of the electromagnetic energy are arranged across atransverse width of the film. In another example, the detector includesa plurality of distinct detectors of the electromagnetic energy. Inanother example, the plurality of distinct detectors of theelectromagnetic energy are arranged across a transverse width of thefilm. In another example, the source and the detector are locatedvertically between a dispenser and set of rollers configured to feed thefilm. In another example, the operation of the foam-in-bag system thatthe controller is configured to control includes one or more of causinga dispenser to stop dispensing the foaming chemical precursors orfurther feeding the film to increase the size of the bag.

In another embodiment, a system includes a foam-in-bag system, a userinterface device, and an arm. The foam-in-bag system is configured toform bags from film and to dispense foaming chemical precursors in tothe bags. The foam-in-bag system includes a controller configured tocontrol at least a portion of operation of the foam-in-bag system. Theuser interface device is communicatively coupled to the controller. Theuser interface device is configured to receive user inputs and to sendsignals indicative of the user inputs to the controller. The arm iscoupled to both a housing of the foam-in-bag system and to the userinterface device. The arm is configured to selectively hold the userinterface device in at least two different positions with respect to thefoam-in-bag system. The arm is configured such that a user is capable ofrepositioning the user interface device between the at least twodifferent positions by hand without the use of tools.

In one example, the arm includes a first arm segment rotatably coupledto the housing. In another example, the system further includes a firstposition bracket configured to engage the first arm segment when the armis positioned to hold the user interface device in a first position ofthe at least two different positions and a second position bracketconfigured to engage the first arm segment when the arm is positioned tohold the user interface device in a second position of the at least twodifferent positions. In another example, the first position bracketincludes a first magnet configured to exert a magnetic force on thefirst arm segment when the arm is positioned to hold the user interfacedevice in the first position, where the magnetic force exerted by thefirst magnet is arranged to bias the first arm segment toward the firstposition bracket when the arm is positioned to hold the user interfacedevice in the first position. In another example, the second positionbracket includes a second magnet configured to exert a magnetic force onthe first arm segment when the arm is positioned to hold the userinterface device in the second position, where the magnetic forceexerted by the second magnet is arranged to bias the first arm segmenttoward the second position bracket when the arm is positioned to holdthe user interface device in the second position. In another example,the system further includes a biasing mechanism configured to exert amechanical force on the first arm segment to bias the first arm segmenttoward one of the first and second position brackets. In anotherexample, the mechanical force causes the first arm segment to berotationally biased towards the one of the first and second positionbrackets.

In another example, the arm further includes a second arm segmentrotatably coupled to the first arm segment and rotatably coupled to theuser interface device. In another example, the second arm segmentincludes two separate bars, each of which is rotatably coupled to thefirst arm segment and rotatably coupled to the user interface device andthe two separate bars of the second arm segment are arranged such thatrotation of the second arm segment about the first arm segment causes arotation of the user interface device about the second arm segment. Inanother example, the arm further includes a latching bracket configuredto selectively hold the two separate bars of the second arm segment withrespect to each other. In another example, the latching bracket includesa disengagement mechanism that, when activated, is configured to permitrotation of the second arm segment with respect to the user interfacedevice. In another example, the second arm segment is rotatably coupledto the user interface device about two axes.

In another embodiment, a system includes a base, a stem, a foam-in-bagsystem, a vertical counterbalance, and a motor. The base is configuredto be placed on a substantially horizontal surface. The stem extendsfrom the base, where the stem includes a movable support that extends ina substantially vertical direction. The foam-in-bag system is configuredto dispense foaming chemical precursor into bag and to form seals in thebags, where at least some components of the foam-in-bag system aresupported by the movable support. The vertical counterbalance isconfigured to exert a force between the base and the movable support tooffset at least a portion of the weight of the movable support and theat least some of the components of the foam-in-bag system that aresupported by the movable support. The motor is configured to selectivelymove the movable support vertically up and down.

In one example, at least one characteristic of the verticalcounterbalance is selected based on an expected weight of the movablesupport and the at least some of the components of the foam-in-bagsystem that are supported by the movable support. In another example,the expected weight is one of an expected minimum weight of the movablesupport and the at least some of the components of the foam-in-bagsystem that are supported by the movable support, an expected maximumweight of the movable support and the at least some of the components ofthe foam-in-bag system that are supported by the movable support, or anexpected average weight of the movable support and the at least some ofthe components of the foam-in-bag system that are supported by themovable support. In another example, the motor is configured to move themovable support at a rate of up to 5 inches per second (12.7 cm persecond) while generating a torque within an acceptable safety range.

In another example, the components of the foam-in-bag system include auser interface device, and the user interface device is supported by themovable support. In another example, the user interface device includesa housing, the user interface device is configured to detect inputsreceived on the housing, and the system is configured to controloperation of the motor based on detected inputs received on the housing.In another example, a front of the user interface device includes afirst vertical input device and a second vertical input device, and thesystem is configured to control movement of the movable support based oninputs received by the first and second vertical input devices. Inanother example, the user interface device is positioned such that thefirst vertical input device is located above a horizontal center of theuser interface device and the second vertical input device is locatedbelow the horizontal center of the user interface device, where thesystem is configured to move the movable support upward based on aninput received by the first vertical input device, and where the systemis configured to move the movable support downward based on an inputreceived by the second vertical input device. In another example, thesystem is further configured to control an upward speed of the movablesupport based on a distance of the input received by the first verticalinput device away from the horizontal center of the user interfacedevice and to control a downward speed of the movable support based on adistance of the input received by the second vertical input device awayfrom the horizontal center of the user interface device. In anotherexample, the system is further configured to control an upward speed ofthe movable support based on a pressure applied by a user when inputtingthe input received by the first vertical input device and to control adownward speed of the movable support based on a pressure applied by auser when inputting the input received by the second vertical inputdevice. In another example, a back of the user interface device includesa touch-sensitive area. In another example, the system is configured tocause movement of the movable support only when an input is received byone the first and second vertical input devices and the touch-sensitivearea registers a touch. In another example, the touch-sensitive area isconfigured to register a touch based on any detected touch of thetouch-sensitive area. In another example, the touch-sensitive area isconfigured to register a touch based on an amount of pressure beingapplied to the touch-sensitive area exceeding a predetermined amount ofpressure. In another example, the touch-sensitive area is approximatelybehind the first and second vertical input devices.

In another example, the motor is configured to be selectively operatedin a low-torque mode and in a high-torque mode. In another example, whenthe motor is operated in low-torque mode, the motor is operable toprovide torque in a range that can move the movable support withassistance of the vertical counterbalance and that cannot move themovable support without assistance of the vertical counterbalance. Inanother example, when the motor is operated in high-torque mode, themotor is operable to provide torque in a range that can move the movablesupport either with or without assistance of the verticalcounterbalance.

BRIEF DESCRIPTION OF THE DRAWING

The foregoing aspects and many of the attendant advantages of thedisclosed subject matter will become more readily appreciated as thesame become better understood by reference to the following detaileddescription, when taken in conjunction with the accompanying drawings,wherein:

FIG. 1A depicts an embodiment of a foam-in-bag system with a firstsource of a first chemical precursor and a second source of a secondchemical precursor, in accordance with the embodiments described herein;

FIG. 1B depicts a schematic diagram of a pumping system for providingthe first and second chemical precursors to the foam-in-bag system shownin FIG. 1A, in accordance with the embodiments described herein;

FIG. 2A depicts an embodiment of a dip tube system that can be used aseither of the dip tube systems depicted in FIGS. 1A and 1B, inaccordance with the embodiments described herein;

FIG. 2B depicts a schematic diagram of the dip tube system shown in FIG.2A, in accordance with the embodiments described herein;

FIG. 3A depicts a perspective view of an embodiment of a dispensermanifolds and a dispenser, collectively, of a foam-in-bag system, inaccordance with the embodiments described herein;

FIGS. 3B, 3C, 3D, 3E, and 3F depict perspective views, respectively, ofan embodiment of the dispenser shown in FIG. 3A, of an embodiment of anoutput block of a second dispenser manifold, of an embodiment of anoutput block of a first dispenser manifold, of an embodiment of an inputblock of a first dispenser manifold, and of an embodiment of an inputblock of the second dispenser manifold, in accordance with theembodiments described herein;

FIGS. 4A, 4B, and 4C depict, respectively, a perspective view of amixing cartridge in a closed orientation, a cross-sectional perspectiveview of the mixing cartridge in the closed orientation, and across-sectional perspective view of the mixing cartridge in an openorientation, in accordance with the embodiments described herein;

FIG. 4D, 4E, and FIG. 4F depict, respectively, a side cross sectionalview of the mixing cartridge and a dispenser drive mechanism with themixing cartridge in the closed configuration, a side cross sectionalview of the mixing cartridge and the dispenser drive mechanism with themixing cartridge in the open configuration, and a perspective view ofthe mixing cartridge in the closed configuration, in accordance with theembodiments described herein;

FIGS. 5A and 5B depict views of an embodiment of a roll of a film web ona spindle system of a foam-in-bag system, in accordance with theembodiments described herein;

FIGS. 5C and 5D depict views of a portion of the spindle system shown inFIG. 5A, in accordance with the embodiments described herein;

FIGS. 6A and 6B depict front and rear perspective views, respectively,of a foam-in-bag system arranged to accommodate a wide roll, inaccordance with the embodiments described herein;

FIGS. 6C and 6D depict front and rear perspective views, respectively,of the foam-in-bag system shown in FIGS. 6A and 6B arranged toaccommodate a narrow roll, in accordance with the embodiments describedherein;

FIGS. 7A, 7B, and 7C depict side, perspective, and cross-sectionalperspective views, respectively, of an embodiment of the longitudinalsealer that can be used in a foam-in-bag system to form longitudinalseals in film, in accordance with the embodiments described herein;

FIGS. 7D and 7E depict side and cross-sectional side views,respectively, of the longitudinal sealer with the arm retracted towardthe housing and the longitudinal sealer installed in the foam-in-bagsystem, in accordance with the embodiments described herein;

FIGS. 7F and 7G depict side and cross-sectional side views,respectively, of the longitudinal sealer with the arm extended out fromthe housing and the longitudinal sealer installed in the foam-in-bagsystem, in accordance with the embodiments described herein;

FIG. 8A depicts an embodiment of a jaw assembly that can be used to formtransverse seals and cuts in film, in accordance with the embodimentsdescribed herein;

FIG. 8B depicts a partial view of this arrangement of a low-adhesionmechanism with respect to the first, second, and third heating elementsin the jaw assembly, in accordance with the embodiments describedherein;

FIG. 8C depicts a view of the low-adhesion mechanism shown in FIG. 8B,in accordance with the embodiments described herein;

FIGS. 8D and 8E depict, respectively, a top view of the jaw assemblywithdrawn from the backing jaw in a lateral direction and a top view ofthe jaw assembly after the jaw assembly has been moved in the lateraldirection up to the backing jaw, in accordance with the embodimentsdescribed herein;

FIGS. 9A to 9D depict instances of a foam-in-bag system that forms bagsfrom film, fills the bags with foaming chemical precursors, and closesthe bags with the foaming chemical precursors inside, in accordance withthe embodiments described herein;

FIGS. 9E to 9I depict instances of a foam-in-bag system that createsbags with foam inside that are more balanced than the bags created bythe foam-in-bag system shown in FIGS. 9A to 9D, in accordance with theembodiments described herein;

FIGS. 9J and 9K depict side views of a foam-in-bag system having frontand rear pinch jaws that enable formation of the more balanced bagcreated by the foam-in-bag system shown in FIGS. 9E to 9I, in accordancewith the embodiments described herein;

FIGS. 10A and 10B depict perspective and cross-sectional side views,respectively, of the foam-in-bag system shown in FIGS. 9A to 9D, inaccordance with the embodiments described herein;

FIGS. 10C and 10D depict an embodiment of proper dispensing and foamingof the foaming chemical precursors by the foam-in-bag system shown inFIGS. 10A and 10B, in accordance with the embodiments described herein;

FIGS. 10E and 10F depict an embodiment of a foam-up failure in thefoam-in-bag system shown in FIGS. 10A and 10B, in accordance with theembodiments described herein;

FIG. 10G depicts a front view of a foam-in-bag system that may be usedto reduce the possibility of a foam-up failure, in accordance with theembodiments described herein;

FIG. 10H depicts a cross-sectional side view of one embodiment of afoam-in-bag system capable of detecting foam-up conditions from outsideof the film, in accordance with the embodiments described herein;

FIG. 10I depicts an instance of a beginning of a foam-up failure anddetection of the foam-up failure by the foam-in-bag system shown in FIG.10H, in accordance with the embodiments described herein;

FIGS. 11A and 11B depict views of an embodiment of a foam-in-bag systemthat includes user interface devices, in accordance with the embodimentsdescribed herein;

FIGS. 11C to 11E depict views of an arm that is capable of being rotated180° to reposition one of the user interface devices between thepositions shown in FIGS. 11A and 11B, in accordance with the embodimentsdescribed herein;

FIGS. 12A and 12B depict views of a foam-in-bag system in lowered andraised positions, respectively, in accordance with the embodimentsdescribed herein;

FIG. 12C depicts an embodiment of the foam-in-bag system shown in FIGS.12A and 12B having a vertical counterbalance in the stem, in accordancewith the embodiments described herein;

FIGS. 12D and 12E depict front and back views, respectively, of anembodiment of a user interface device with controls to raise and lower amovable support in the stem of the foam-in-bag system shown in FIG. 12C,in accordance with the embodiments described herein;

FIG. 12F depicts an embodiment of a user's hand grasping or pinching theuser interface device shown in FIGS. 12D and 12E to control movement ofthe movable support, in accordance with the embodiments describedherein;

FIG. 13A depicts an embodiment of a system that dispenses solvent in acontrolled manner to limit the amount of solvent used;

FIG. 13B depicts a chart showing an example of flow rates of the solventcaused by controlling the pump shown in FIG. 13A over the course of ashot of the first and second chemical precursors;

FIG. 14 depicts an example embodiment of a system that may be used toimplement some or all of the embodiments described herein; and

FIG. 15 depicts a block diagram of an embodiment of a computing device,in accordance with the embodiments described herein.

DETAILED DESCRIPTION

Polyurethane foam may be formed by mixing foaming chemical precursors,such as an isocyanate compound with a hydroxyl-containing material, suchas a polyol (i.e., a compound that contains multiple hydroxyl groups),typically in the presence of water and a catalyst. As the isocyanate andpolyol foam precursors react in the presence of the catalyst to formpolyurethane, the water reacts with isocyanate to produce carbon dioxidegas, which acts as a blowing or foaming agent to expand the polyurethaneinto a foamed cellular structure (i.e., a polyurethane foam).

With foam-in-bag packaging, the foam precursors may be mixed anddispensed into flexible plastic bags, for example, as the bags areformed from plastic film. As the precursors react to form expanding foamwithin the bag, the bag may be sealed closed. The bag may then be placedinto a box holding an object to be cushioned. The foam tends to expandwithin the bag into the available space inside the box to form a customfoam cushions around the packaged object. Machines for producingfoam-in-bag cushions are described, for example, in U.S. Pat. Nos.4,800,708; 4,854,109; 5,376,219; 5,727,370; 6,003,288; 6,550,229; and6,675,557; each of which is incorporated herein in its entirety byreference; and such machines are available, for example, from Sealed AirCorporation under the Instapak®, SpeedyPacker Insight®, and Instapacker®trademarks.

Machines that produce foam-in-bag packaging may use a dispenser in whichfoam precursors enter the dispenser to mix with one another in aninternal mixing chamber of the dispenser to form a foamable composition.The resultant foamable composition then exits the dispenser via adischarge outlet. See for example, U.S. Pat. Nos. 4,898,327 and5,255,847, each of which is incorporated herein in its entirety byreference.

In some embodiments, foam-in-bag systems include sources of chemicalprecursors. When mixed, these chemical precursors react to form foamthat expands to fill a volume that is many times greater (e.g., hundredsof times greater) than the volume of the chemical precursors themselves.

Depicted in FIG. 1A is an embodiment of a foam-in-bag system 100 with afirst source 102 _(A) of a first chemical precursor 104 _(A) and asecond source 102 _(B) of a second chemical precursor 104 _(B). Wherethe figures herein show multiple instances of an item using the samereference number and a different subscript to differentiate theindividual instances (e.g., the first source 102 _(A) and the secondsource 102 _(B)), the items collectively will be referred to hereinusing only the reference number (e.g., the first and second sources102). The first and second sources 102 hold the first and secondchemical precursors 104 separately and allow the foam-in-bag system 100to draw the first and second chemical precursors 104 for dispensing intoa formed bag. In some examples, the first and second sources 102 aredrums, barrels, tanks, vats, bottles, or other containers that arecapable of holding the chemical precursors. In the depicted embodiment,the first and second sources 102 are in the form of metal drums. Each ofthe first and second sources 102 holds an amount of the first and secondchemical precursors 104, respectively, and allows the foam-in-bag system100 to draw out the first and second chemical precursors 104 over timeas the foam-in-bag system 100 forms bags and dispenses small amounts ofthe first and second chemical precursors 104 into each bag.

In addition to the depiction shown in FIG. 1A, a schematic diagram of apumping system 106 for providing the first and second chemicalprecursors 104 to the foam-in-bag system 100 is shown in FIG. 1B. Thepumping system 106 includes a first dip tube system 108 _(A) capable ofdrawing the first chemical precursor 104 _(A) out of the first source102 _(A) and a second dip tube system 108 _(B) capable of drawing thesecond chemical precursor 104 _(B) out of the second source 102 _(B). Insome embodiments, the first and second dip tube systems 108 have aweight that allows a user to lift each of the first and second dip tubesystems 108 out of the first and second sources 102 manually and replacethe first and second dip tube systems 108 into different sources ofchemical precursors manually without the use of tools.

In the depicted embodiment, the first dip tube system 108 _(A) includesa dip tube 109 _(A) through which a feed line 110 _(A) passes. The feedline 110 _(A) is usable to draw the first chemical precursor 104 _(A)out of the first source 102 _(A). The first dip tube system 108 _(A)also includes a dip tube 111 _(A) through which a return line 112 _(A)passes. The return line 112 _(A) is usable for priming and/or pressurebleeding the feed line 110 _(A). The dip tubes 109 _(A) and 111 _(A) arecoupled to a manifold 113 _(A) that is configured to remain outside ofthe source 102 _(A). Similarly, the second dip tube system 108 _(B)includes a dip tube 109 _(B) through which a feed line 110 _(B) passes.The feed line 110 _(B) is usable to draw the second chemical precursor104 _(B) out of the second source 102 _(B). The first dip tube system108 _(B) also includes a dip tube 111 _(B) through which a return line112 _(B) passes. The return line 112 _(B) is usable for priming and/orpressure bleeding the feed line 110 _(B). The dip tubes 109 _(B) and 111_(B) are coupled to a manifold 113 _(B) that is configured to remainoutside of the source 102 _(B). In the depicted embodiment, the diptubes 109 _(A) and 111 _(A) are separate dip tubes and the dip tubes 109_(B) and 111 _(B) are separate dip tubes. In other embodiments, the diptubes 109 _(A) and 111 _(A) can be a single dip tube through which bothof the feed line 110 _(A) and the return line 112 _(A) pass and the diptubes 109 _(B) and 111 _(B) can be a single dip tube through which bothof the feed line 110 _(B) and the return line 112 _(B) pass.

The feed line 110 _(A) includes filters 114 _(A) to filter the firstchemical precursor 104 _(A) passing through the feed line 110 _(A) and acheck valve 116 _(A) configured to permit the first chemical precursor104 _(A) to pass only in one direction. The feed line 110 _(B) includesfilters 114 _(B) to filter the second chemical precursor 104 _(B)passing through the feed line 110 _(B) and a check valve 116 _(B)configured to permit the second chemical precursor 104 _(B) to pass onlyin one direction. In some embodiments, the check valves 116 are umbrellastyle one-way valves configured to prevent residual chemical fromflowing back out when the dip tube systems 108 are changed from an emptycontainer to a full container. In some embodiments, the filters 114upstream of the check valves 116 are coarse filters configured toprevent large debris from reaching the check valves 116 and the filters114 downstream of the check valves 116 are fine filters configured toprevent small debris from passing through the feed lines 110 with thechemical precursors 104. Various embodiments of the first and second diptube systems 108 are described in greater detail below.

The pumping system 106 also includes a first transfer pump system 118_(A) and a second transfer pump system 118 _(B). A hose 120 _(A) passesbetween the manifold 113 _(A) of the first dip tube system 108 _(A) andthe first transfer pump system 118 _(A). The feed line 110 _(A) passesthrough the hose 120 _(A) between the manifold 113 _(A) and the firsttransfer pump system 118 _(A). A hose 121 _(A) passes between themanifold 113 _(A) of the first dip tube system 108 _(A) and the firsttransfer pump system 118 _(A). The return line 112 _(A) passes throughthe hose 121 _(A) between the manifold 113 _(A) and the first transferpump system 118 _(A). A hose 120 _(B) passes between the manifold 113_(B) of the second dip tube system 108 _(B) and the second transfer pumpsystem 118 _(B). The feed line 110 _(B) passes through the hose 120 _(B)between the manifold 113 _(B) and the second transfer pump system 118_(B). A hose 121 _(B) passes between the manifold 113 _(B) of the firstdip tube system 108 _(B) and the second transfer pump system 118 _(B).The return line 112 _(B) passes through the hose 121 _(B) between themanifold 113 _(B) and the second transfer pump system 118 _(B). In theembodiment shown in FIG. 1A, the transfer pump systems 118 are locatedin a housing that is external to the sources 102 and external to thefoam-in-bag system 100. In other embodiments, the transfer pump systems118 can be located in the sources 102 or located in the foam-in-bagsystem 100. While the embodiment depicted in FIG. 1B shows the hoses 120and 121 being separate hoses, it will be apparent that other embodimentsmay include a single hose that carries both the feed line 110 _(A) andthe return line 112 _(A) between the manifold 113 _(A) and the firsttransfer pump system 118 _(A) and a single hose that carries both thefeed line 110 _(B) and the return line 112 _(B) between the manifold 113_(B) and the second transfer pump system 118 _(B).

In some embodiments, the feed lines 110, the return lines 112, and/orthe hoses 120 and 121 may be transparent or semi-transparent, whichallows an outside observer to see whether chemical precursors 104 arepassing through the feed lines 110 and/or the return lines 112 orwhether there is any gas (e.g., an air bubble) in the feed lines 110and/or the return lines 112. In other embodiments, the feed lines 110,the return lines 112, and/or the hoses 120 and 121 may not betransparent or semi-transparent.

The first transfer pump system 118 _(A) includes a transfer pump 122_(A) on the feed line 110 _(A) and the second transfer pump system 118_(B) includes a transfer pump 122 _(B) on the feed line 110 _(B). Thetransfer pumps 122 may be any type of pump that is capable of drawingthe chemical precursors 104 out of the sources 102. In the depictedembodiment, the transfer pumps 122 are magnetically coupled gerotorpumps. A gerotor pump is a positive displacement pump that uses innerand outer rotors with offset axes that cause dynamically-changing innervolumes to drawn in fluid and push out fluid. The magnetic couplingsallow these gerotor pumps to locate and operate while minimizing oreliminating seal failures and resultant chemical leakage anywhereoutside of the sources 102. In some embodiments, the gerotor pumps areconfigured to have an operational throughput of 1.1 cubic centimetersper revolution (cc/rev), although the transfer pumps 122 may be expectedto operate at a lower throughput during normal operation due tooperating conditions (e.g., back pressure in the feed lines 110,differing viscosities of the chemical precursors 104). In otherembodiments, the transfer pumps 122 include one more of a piston pump, adiaphragm pump, a screw pump, a gear pump, an hydraulic pump, aperistaltic pump, or any other type of pump.

The first transfer pump system 118 _(A) includes a check valve 124 _(A)downstream from the transfer pump 122 _(A) on the feed line 110 _(A) andthe second transfer pump system 118 _(B) includes a check valve 124 _(B)downstream from the transfer pump 122 _(B) on the feed line 110 _(B). Insome embodiments, the check valves 124 are mounted to the outlets of thetransfer pumps 122. The check valves 124 permit flow of the chemicalprecursors 104 substantially in only one direction in the feed lines 110(e.g., the downstream direction). The check valves 124 also maintainsthe pressure in the feed lines 110 upstream of the check valves 124without the need for the transfer pumps 122 to idle merely to maintainpressure in the feed lines 110. In some embodiments, the check valves124 are steel ball and seat check valves configured to prevent backflowduring idle to reduce wear on the transfer pumps 122. One drawback withthe use of gerotor pumps is that fluid can bleed upstream through thegerotor gears when the gerotor pump is idling. Avoiding the need for thetransfer pumps 122 to idle will eliminate this drawback.

The first transfer pump system 118 _(A) includes a pressure transducer126 _(A) and a temperature sensor 128 _(A) upstream from the transferpump 122 _(A) on the feed line 110 _(A). The second transfer pump system118 _(B) includes a pressure transducer 126 _(B) and a temperaturesensor 128B upstream from the transfer pump 122 _(B) on the feed line110 _(B). The pressure transducers 126 are configured to provide anindication of the pressure in the feed lines 110 upstream of the checkvalves 124. In some embodiments, the pressure transducers 126 areconfigured to detect pressure within a range between −15 psi and +5 psi.The temperature sensors 128 are configured to provide an indication ofthe temperature of the chemical precursor 104 in the feed lines 110upstream of the check valves 124.

The first transfer pump system 118 _(A) includes a bleed valve 130 _(A)and a prime valve 132 _(A) arranged in parallel on the return line 112_(A), with a filter 134 _(A) located on the parallel line with the bleedvalve 130 _(A). The second transfer pump system 118 _(B) includes ableed valve 130 _(B) and a prime valve 132 _(B) arranged in parallel onthe return line 112 _(B), with a filter 134 _(B) located on the parallelline with the bleed valve 130 _(B). In some embodiments, the bleedvalves 130 have relatively small openings and the filters 134 decreasethe likelihood of debris in the chemical precursor clogging the bleedvalves 130. The bleed valves 130 and prime valves 132 can be selectivelyand independently opened and closed to allow the chemical precursors 104to flow through the return lines 112 such that the chemical precursors104 are withdrawn from the feed lines 110 at points that are downstreamof the check valves 124 and returned to the sources 102.

The bleed valves 130 and prime valves 132 can also be selectively andindependently opened and closed to prevent flow of the chemicalprecursors 104 through the return lines 112. Examples of when the bleedvalves 130 and prime valves 132 may be opened or closed are discussedbelow. In some embodiments, the bleed valves 130 have a higher pressurerating than the prime valves 132. In one example, the bleed valves 130are rated to 850 psi (5.86 MPa) and the prime valves 132 are rated to 50psi (345 kPa). In some embodiments, the bleed valves 130 are configuredto be open when they are unpowered and the prime valves 132 areconfigured to be closed when they are unpowered.

The pumping system 106 also includes a first metering pump system 136_(A) and a second metering pump system 136 _(B). In the depictedembodiment, the metering pump systems 136 are located in the base of thefoam-in-bag system 100. In other embodiments, the metering pump systems136 can be located elsewhere the foam-in-bag system 100 or external tothe foam-in-bag system 100. A hose 138 _(A) passes between the firsttransfer pump system 118 _(A) and the first metering pump system 136_(A) and a hose 138 _(B) passes between the second transfer pump system118 _(B) and the second metering pump system 136 _(B). The portions ofthe feed lines 110 are located in the hoses 138. The hoses 138 may be avariety of different lengths, such as anywhere from 1 foot (0.3 meters)to 100 feet (30 meters) or greater than 100 feet (30 meters). Becausethe hoses 138 to be a variety of different lengths, the sources 102 canbe placed at a number of different locations with respect to thefoam-in-bag system 100 and the length of the hoses 138 can be selectedso that the hoses 138 are an appropriate length for the distance betweenthe sources 102 and the foam-in-bag system 100. In some embodiments, asthe lengths of the hoses 138 are increased, the inner diameters of thefeed lines 110 may be increased to minimize pressure drop over thelonger length of the feed lines 110.

The first metering pump system 136 _(A) includes a metering pump 140_(A) on the feed line 110 _(A) and the second metering pump system 136_(B) includes a metering pump 140 _(B) on the feed line 110 _(B). Thetransfer pumps 122 may be any type of pump that is capable of pumpingthe chemical precursors 104 through the feed lines 110. In the depictedembodiment, the metering pumps 140 are magnetically coupled gerotorpumps. In some embodiments, the gerotor pumps are configured to have anoperational throughput of 1.1 cc/rev, and the metering pumps 140 may beexpected to operate at or near that operational throughput during normaloperation (e.g., such as under the condition where the inlet pressureand the outlet pressure of the metering pumps 140 are the same or closeto each other). In other embodiments, the metering pumps 140 include onemore of a piston pump, a diaphragm pump, a screw pump, a gear pump, anhydraulic pump, a peristaltic pump, or any other type of pump.

The first metering pump system 136 _(A) includes an input pressuretransducer 142 _(A) and an outlet pressure transducer 144 _(A). Theinput pressure transducers 142 are located upstream of the meteringpumps 140 on the feed lines 110 and the outlet pressure transducers 144are located downstream of the metering pumps 140. In some embodiments,the input pressure transducers 142 are coupled to an input of themetering pumps 140 and the outlet pressure transducers 144 are coupledto an output of the metering pumps 140. In some embodiments, the inputand output pressure transducers 142 and 144 are configured to detectpressure within a range between 0 psi and 1000 psi.

In some embodiments, the operation of the metering pumps 140 arecontrolled in order to minimize the pressure differential between thepressure at the input pressure transducers 142 and the pressure at theoutlet pressure transducers 144. In other words, in some embodiments,the operation of the metering pump 140 _(A) is controlled in order tominimize the pressure differential between the pressure at the inputpressure transducer 142 _(A) and the pressure at the outlet pressuretransducer 144 _(A). Similarly, in some embodiments, the operation ofthe metering pump 140 _(B) is controlled in order to minimize thepressure differential between the pressure at the input pressuretransducer 142 _(B) and the pressure at the outlet pressure transducer144 _(B).

The pumping system 106 also includes a first dispenser manifold 146 _(A)and a second dispenser manifold 146 _(B). A hose 148 _(A) passes betweenthe first metering pump system 136 _(A) and the first dispenser manifold146 _(A) and a hose 148 _(B) passes between the second metering pumpsystem 136 _(B) and the second dispenser manifold 146 _(B). In thedepicted embodiment, the hose 148 _(A) includes a heating element 150_(A), a temperature sensor 152 _(A), and a thermal protector 154 _(A).In the depicted embodiment, the hose 148 _(B) includes a heating element150 _(B) and a thermal protector 154 _(B). The heating elements 150 areconfigured to be in direct contact with and heat the chemical precursor104 in the feed line 110. In the case of hose 148 _(A), the indicationsof temperature generated by the temperature sensor 152 _(A) may be usedto control the heating element 150 _(A) and/or the heating element 150_(B) to cause one or both of the chemical precursors 104 to be heated toa particular temperature or to be within a particular temperature range.In some embodiments, each of the heating elements 150 is a heater wirethat is directly in contact with the chemical precursors 104 in the feedlines 110. In some cases, the heater wire is rated to 25 ohms, linevoltage (e.g., 208 VAC), and/or 1750 watts. The thermal protectors 154are configured to generate a signal indicative of an overheatingcondition, which may be used to stop operation of some or all of thepumping system 106.

The first dispenser manifold 146 _(A) includes an input temperaturesensor 156 _(A) configured to be in contact with and determine atemperature of the first chemical precursor 104 _(A) as it is receivedin the first dispenser manifold 146 _(A) from the hose 148 _(A). Thefirst dispenser manifold 146 _(A) also includes an input block 158 _(A)(e.g., an aluminum block) through which the feed line 110 _(A) passes.The input block 158 _(A) includes a heating element 160 _(A) configuredto heat the input block 158 _(A), a temperature sensor 162 _(A)configured to determine a temperature of the input block 158 _(A), and athermal protector 164 _(A) configured to generate a signal indicative ofan overheating condition of the input block 158 _(A). The firstdispenser manifold 146 _(A) also includes a filter 166 _(A) configuredto filter the first chemical precursor 104 _(A) in the portion of thefeed line 110 _(A) that passes through the input block 158 _(A). Thefirst dispenser manifold 146 _(A) also includes an output block 168 _(A)(e.g., an aluminum block) through which the feed line 110 _(A) passes.The output block 168 _(A) includes a heating element 170 _(A) configuredto heat the output block 168 _(A) and a temperature sensor 172 _(A)configured to determine a temperature of the input block 168 _(A).Signals generated by any or all of the temperature sensors 156 _(A), 162_(A), and 172 _(A) may be used to control operation of one or both ofthe heating elements 160 _(A) and 170 _(A).

The second dispenser manifold 146 _(B) includes an input temperaturesensor 156 _(B) configured to be in contact with and determine atemperature of the second chemical precursor 104 _(B) as it is receivedin the second dispenser manifold 146 _(B) from the hose 148 _(B). Thesecond dispenser manifold 146 _(B) also includes an input block 158 _(B)(e.g., an aluminum block) through which the feed line 110 _(B) passes.The input block 158 _(B) includes a heating element 160 _(B) configuredto heat the input block 158 _(B), a temperature sensor 162 _(B)configured to determine a temperature of the input block 158 _(B), and athermal protector 164 _(B) configured to generate a signal indicative ofan overheating condition of the input block 158 _(B). The seconddispenser manifold 146 _(B) also includes a filter 166 _(B) configuredto filter the second chemical precursor 104 _(B) in the portion of thefeed line 110 _(B) that passes through the input block 158 _(B). Thesecond dispenser manifold 146 _(B) also includes an output block 168_(B) (e.g., an aluminum block) through which the feed line 110 _(B)passes. The output block 168 _(B) includes a heating element 170 _(B)configured to heat the output block 168 _(B) and a temperature sensor172 _(B) configured to determine a temperature of the input block 168_(B). Signals generated by any or all of the temperature sensors 156_(B), 162 _(B), and 172 _(B) may be used to control operation of one orboth of the heating elements 160 _(B) and 170 _(B).

In some embodiments, the heating elements 160 are configured to heat theinput blocks 158. In some cases, the heating elements 160 are cartridgestyle heaters that are in direct contact with the input blocks 158 butnot in direct contact with the chemical precursors 104 passing throughthe feed lines 110. In some examples, the heating elements 160 arecartridge style heaters rated to 500 watts. In some embodiments, theheating elements 170 are configured to heat the output blocks 168. Insome cases, the heating elements 170 are cartridge style heaters thatare in direct contact with the output blocks 168 but not in directcontact with the chemical precursors 104 passing through the feed lines110. In some examples, the heating elements 170 are cartridge styleheaters rated to 150 watts.

The feed lines 110 pass from the dispenser manifolds 146 into adispenser 174. The dispenser 174 includes a mixing cartridge manifold176 that dispenses the first and second chemical precursors 104 _(A) and104 _(B) into formed bags. The mixing cartridge manifold 176 includes amixing cartridge 178 configured to be selectively controlled to dispensespecific amounts of the first and second chemical precursors 104 _(A)and 104 _(B) into formed bags. In some embodiments, the mixing cartridge178 is driven by a motor (e.g., a servo motor) to provide control of theratio of dispensing of the first chemical precursor 104 _(A) and thesecond chemical precursor 104 _(B). This also allows the motor controlsto be closely synchronized with the opening and closing of the mixingcartridge 178. The mixing cartridge manifold 176 includes a heatingelement 180 configured to heat the mixing cartridge manifold 176 and atemperature sensor 182 configured to determine a temperature of themixing cartridge manifold 176. Signals generated the temperature sensor182 may be used to control operation of the heating element 180. In someembodiments, the heating element 180 is configured to heat the mixingcartridge manifold 176. In some cases, the heating element 180 is acartridge style heater that is in direct contact with the mixingcartridge manifold 176 but not in direct contact with the chemicalprecursors 104. In some examples, the heating element 180 is a cartridgestyle heater rated to 80 watts. In some embodiments, the mixingcartridge 178 has relatively small orifices to control the amount of thechemical precursors 104 being dispensed. In order to avoid clogging themixing cartridge 178, the filters 166 in the dispenser manifolds 146 canbe fine filters to filter out small debris in the feed lines 110 beforethe chemical precursors 104 reach the mixing cartridge 178.

The dispenser 174 also includes a manual shutoff valve 184 _(A) on thefeed line 110 _(A) before the first chemical precursor 104 _(A) reachesthe mixing cartridge manifold 176 and a manual shutoff valve 184 _(B) onthe feed line 110 _(B) before the second chemical precursor 104 _(B)reaches the mixing cartridge manifold 176. The manual shutoff valves 184can be closed manually by a user before the mixing cartridge manifold176 and/or the mixing cartridge 178 is removed, such as for replacementof the mixing cartridge manifold 176 and/or the mixing cartridge 178 orcleaning of the mixing cartridge manifold 176 and/or the mixingcartridge 178. The ability to manually close the manual shutoff valves184 allows a user to ensure that the chemical precursors 104 do not leakwhen the mixing cartridge manifold 176 and/or the mixing cartridge 178is removed. In some embodiments, the manual shutoff valves 184 are ballvalves.

During normal operation of the foam-in-bag system 100, the foam-in-bagsystem 100 will form bags, dispense chemical precursors into each formedbag, and then seal the bag after the chemical precursors have beendispensed. The chemical precursors then foam up inside the sealed bag.In this operation, the mixing cartridge 178 will dispense the chemicalprecursors intermittently. The mixing cartridge 178 dispenses an amountof the chemical precursors (also called a “shot” of the chemicalprecursors) into each bag. The foam-in-bag system 100 requires time toseal the bag into which the shot has been dispensed and time to form thenext bag before the next shot of chemical precursors is dispensed by themixing cartridge 178.

In some embodiments, components of the pumping system 106 are controlledto cause the chemical precursors 104 to flow at specific flow rates inthe feed lines 110 and/or to cause specific amounts of chemicalprecursors 104 to be dispensed by the mixing cartridge 178. For example,during a shot of the chemical precursors, the metering pumps 140 aredriven at a target speed (e.g., a target rotation per minute),determined by a desired flow rate of the chemical precursors 104 and adesired ratio of the chemical precursors 104. In some embodiments, themetering pumps 140 are accelerated to a set speed in as short a time asis feasible and then held at the set speed for a time of the duration ofthe shot as precisely as feasible. In some embodiments, the transferpumps 122 are also driven in order to minimize or eliminate the pressuredifferential between the input and output of the metering pumps 140. Forexample, the speed of the transfer pumps 122 can be controlled tominimize or eliminate the difference between the signals generated bythe respective set of input pressure transducers 142 and the outletpressure transducers 144. Under many conditions, this control of thetransfer pumps 122 will cause the speed of the transfer pumps 122 to behigher than the speed of the metering pumps 140.

As can be seen in FIG. 1B, the depicted embodiment of the pumping system106 includes four pumps: the two transfer pumps 122 and the two meteringpumps 140. While it is possible to pump the first and second chemicalprecursors from the sources 102 to the dispenser 174 using two pumpsonly (i.e., one pump for the first chemical precursor 104 _(A) and onepump for the second chemical precursor 104 _(B)), the four-pump pumpingsystem 106 provide increased precision and control of flow rate of thechemical precursors 104 and the timing of the flow of the chemicalprecursors 104. In some embodiments, it is desirable for the chemicalprecursors 104 to begin flowing out of the dispenser as soon as possibleafter the mixing cartridge 178 is opened. This may require a high rateof acceleration by the pumping system. The combination of metering pumps140 to meet the acceleration demands of the dispenser and the transferpumps 122 to provide appropriate flow rates out of the sources 102 makethis high rate of acceleration possible. In some embodiments, thetransfer pumps 122 and the metering pumps 140 are servo motors (e.g.,gerotors) in order to meet the speed and control demands of the pumpingsystem 106.

As noted above, the bleed valves 130 and the prime valves 132 in thetransfer pump systems 118 can be selectively and independently openedand closed to allow the chemical precursors 104 to flow through thereturn lines 112 such that the chemical precursors 104 are withdrawnfrom the feed lines 110 at points that are downstream of the checkvalves 124 and returned to the sources 102. For example, the bleedvalves 130 can be opened to allow chemical precursors 104 to pass fromthe feed lines 110 into the return lines 112. This may be used toprevent pressure build up in the return lines 112 downstream of thecheck valves 124. In some example, the bleed valves 130 is opened(either manually or automatically) to control the pressure within apredetermined pressure range at or near a pressure that is in the feedlines 110 downstream of the transfer pumps 122. In some cases, thepressure in the feed lines increases due to thermal expansion when thechemical precursors 104 are heated in the feed lines 110. In othercases, the prime valves 132 can be opened to allow chemical precursors104 and/or gas (e.g., air) to pass from the feed lines 110 into thereturn lines 112. This may be helpful when priming the pumping system106 after the dip tube systems 108 are changed from one container (e.g.,an empty drum) to another container (e.g., a full drum).

In some embodiments, the transfer pumps 122 can be drum pumps. In theseembodiments, the prime valves 132 and their associated controls may beomitted from the pumping system 106. In these embodiments, a bleedvalves 130 may still be used. If the bleed valves 130 were located onthe manifolds of the transfer pump systems 118, then the return lines112 may be omitted from the pumping system 106.

The pumping system 106 has a number of benefits. In one example, thepumping system 106 provides reliable control of flow rates and ratios ofthe chemical precursors 104 when dispensing any type of shots. Thecontrol of the ratios and flow rates of the chemical precursors 104allows for the resultant foam to have substantially the same qualityunder a variety of conditions of the shots being dispensed. For example,the foam quality at the very beginning of a shot will be the same as itis at the end of the shot. In another example, there is no lead or lagon the pressure or flow of the chemical precursors 104. In anotherexample, when flow rates of the chemical precursors 104 are wellregulated, the amount of the chemical precursors 104 dispensed into bagsand the amount of the resultant foam in the bags is better controlled.In another example, the dip tube systems 108 can be simply removed fromone source (e.g., drum) when the source is empty and inserted intoanother source that is full without the need for extensive manual workby a user because the pumping system 106 can automatically prime the diptube systems 108 after they are inserted into new containers.

In practical benefits, the controls in the pumping system 106 can resultin cost savings for an operator of the foam-in-bag system 100. Forexample, when an improper ratio of the first and second chemicalprecursors 104 _(A) and 104 _(B) are dispensed into a bag, some amountof one of the first and second chemical precursors 104 _(A) and 104 _(B)will not react in the bag. This results in the unused amounts of thechemical precursors 104 that add cost to each bag without adding anyvalue. In another example, the use of two pumps on each of the feedlines 110 (i.e., one of the transfer pumps 122 and one of the meteringpumps 140) reduces the overall wear that would be incurred if only onepump was used on the each of the feed lines 110. This reduced wear isespecially the case if one or both of the chemical precursors 104 is anon-lubricating chemical precursor. Reduced wear on the pumps meansfewer maintenance needs, less downtime for maintenance, lowermaintenance costs, greater metering accuracy by the pumps, longer peakefficiency of the pumping system 106, and more efficient use of thechemical precursors 104 by the pumping system 106.

Another benefit of the pumping system 106 is the ability to monitor thecondition of the four pumps in the pumping system 106. In typicaloperation, the transfer pumps 122 are expected to operate at a higherrate (e.g., higher revolutions per minute (RPM)) than the metering pumps140. When the transfer pumps 122 are new, they are more efficient, andwill run at a lower rate. However, as the transfer pumps 122 starts towear, they will turn at higher rates to keep up. Thus, the condition ofthe transfer pumps 122 can be monitored by comparing the rates of thetransfer pumps 122 with the rates of the metering pumps 140. If thedifferential in rates of the transfer pumps 122 and the metering pumps140 exceeds a certain level, a signal may be generated to clean orchange the transfer pumps 122.

Depicted in FIG. 2A is an embodiment of a dip tube system 200 that canbe used as either of the dip tube systems 108 depicted in FIGS. 1A and1B. The dip tube system 200 is shown in FIG. 2A having been insertedinto a source 202 of chemical precursor 204. The dip tube system 200includes a dip tube 209 configured to be inserted through an opening inthe source 202 into the chemical precursor 204 in the source 202. Thedip tube system 200 also includes a manifold 213 that is coupled to thedip tube 209 and remains outside of the source 202. The dip tube system200 is capable of being used to siphon the chemical precursor 204 out ofthe source 202.

Also depicted in FIG. 2A is a transfer pump system 218 that is coupledto the manifold 213 of the dip tube system 200 via a hose 220. The diptube system 200, the source 202 of the chemical precursor 204, thetransfer pump system 218, and the hose 220 are all depicted in aschematic diagram in FIG. 2B. As depicted in FIG. 2B, the transfer pumpsystem 218 can also be coupled to the manifold 213 of the dip tubesystem 200 via a hose 221, although the hose 221 is not depicted in FIG.2A.

A feed line 210 usable to draw the chemical precursor 204 out of thesource 202 and a return line 212 usable for priming and/or pressurebleeding the feed line 210. The feed line 210 and the return line 212pass through the dip tube 209 and the manifold 213 of the dip tubesystem 200, through the hoses 220 and 221, respectively, and through thetransfer pump system 218. In the depicted embodiments, the feed line 210includes filters 214 to filter the chemical precursor 204 passingthrough the feed line 210 and a check valve 216 configured to permit thechemical precursor 204 to pass substantially only in the downstreamdirection. In some embodiments, the check valve 216 is an umbrella styleone-way valve configured to prevent residual chemical precursor 204 fromflowing back out when the dip tube system 200 is changed from an emptycontainer to a full container. In some embodiments, the filter 214upstream of the check valve 216 is a coarse filter configured to preventlarge debris from reaching the check valves 116 and the filter 214downstream of the check valve 216 is a fine filter configured to preventsmall debris from passing through the feed lines 210 with the chemicalprecursor 204.

The transfer pump system 218 includes a transfer pump 222 on the feedline 210. The transfer pump 222 may be any type of pump that is capableof drawing the chemical precursor 204 out of the source 202. In thedepicted embodiment, the transfer pump 222 is a gerotor pump. In someembodiments, the gerotor pump is configured to have an operationalthroughput of 1.1 cubic centimeters per revolution (cc/rev). In otherembodiments, the transfer pump 222 includes one or more of a pistonpump, a diaphragm pump, a screw pump, a gear pump, an hydraulic pump, aperistaltic pump, or any other type of pump.

The transfer pump system 218 includes a check valve 224 downstream fromthe transfer pump 222 on the feed line 210. In some embodiments, thecheck valve 224 is mounted to the outlet of the transfer pump 222. Thecheck valve 224 permits flow of the chemical precursor 204 insubstantially only the downstream direction in the feed line 210. Thecheck valve 224 also monitor the pressure in the feed line 210 upstreamof the check valve 224. In some embodiments, the check valve 224 is asteel ball and seat check valve configured to prevent backflow duringidle to reduce wear on the transfer pump 222.

The transfer pump system 218 includes a pressure transducer 226 and atemperature sensor 228 upstream from the transfer pump 222 on the feedline 210. The pressure transducer 226 is configured to provide anindication of the pressure in the feed line 210 upstream of the checkvalve 224. In some embodiments, the pressure transducer 226 isconfigured to detect pressure within a range between −15 psi and +5 psi.The temperature sensor 228 is configured to provide an indication of thetemperature of the chemical precursor 204 in the feed line 210 upstreamof the check valve 224.

The transfer pump system 218 includes a bleed valve 230 and a primevalve 232 arranged in parallel on the return line 212, with a filter 234located on the parallel line with the bleed valve 230. In someembodiments, the bleed valve 230 has a relatively small opening and thefilter 234 decreases the likelihood of debris in the chemical precursor204 clogging the bleed valve 230. The bleed valve 230 and the primevalve 232 can be selectively and independently opened and closed toallow the chemical precursor 204 to flow through the return line 212such that the chemical precursor 204 is withdrawn from the feed line 210at a point that is downstream of the check valve 224 and returned to thesource 202. In some embodiments, the bleed valve 230 opens a higherpressure than the prime valve 232. In one example, the bleed valve 230is configured to open at 850 psi (5.86 MPa) and the prime valve 232 isconfigured to open at 50 psi (345 kPa). In some embodiments, the bleedvalve 230 is configured to be open when it is unpowered and the primevalve 232 is configured to be closed when it is unpowered.

There are a number of benefits attained by using the dip tube system 200with the transfer pump system 218 depicted in FIGS. 2A and 2B. Forexample, the use of the parallel bleed and prime valves 230 and 232 onthe return line 212 facilitates priming of the dip tube system 200 toclear the feed line 210 of gas (e.g., air). From a user's perspective,the user can merely insert the dip tube system 200 into a source ofchemical precursor, and the transfer pump system 218 can prime the diptube system 200 automatically without any further user work. In anotherexample, the use of the parallel bleed and prime valves 230 and 232 onthe return line 212 facilitates pressure relief within the feed line 210during idle, which improve foam quality and consistency when a shot ofthe chemical precursor 204 is dispensed with another chemical precursor.In another example, when the bleed valve 230 is configured to be openwhen it is unpowered, the bleed valve 230 will open when the transferpump system 218 is turned off to automatically bring the pressure in thefeed line 210 to zero when the transfer pump system 218 is turned off.Having zero pressure in the feed line 210 when the transfer pump system218 is turned off enhances safety of the system.

Another benefit to the dip tube system 200 depicted in FIGS. 2A and 2Bis the ability to place the filters 214 inside the portion of the feedline 210 in the dip tube 209. In some embodiments, one or more of thefilters 214 is a long, fine mesh screen filter attached to the insidediameter of the feed line 210. This arrangement allows for the filter tohave a very large surface area. In some embodiments, the filters 214 canbe located along a majority of the length of the dip tube 209. This mayallow for the filters 114 to be large enough to be usable for the entireexpected life of the dip tube system 200 without any maintenance. Theability to avoid maintenance of the filters 214 can be extremelybeneficial in the case where the chemical precursor 204 is hazardous orotherwise dangerous. In addition, some types of chemical precursors willform crystals on the surface of the filters 214 if the filters areexposed to air, and the ability to keep the filters 214 substantiallysubmerged in the chemical precursor 204. These crystals are potentiallyharmful to the feed line 210, a downstream dispenser (e.g., dispenser174), or other parts of a pumping system (e.g., pumping system 106), andkeeping the filters 214 substantially submerged in the chemicalprecursor 204 deters the formation of these crystals.

In another example, the pressure transducer 226 in the feed line 210upstream of the transfer pump 222 provides a number of benefits. In oneexample, the pressure measurement by the pressure transducer 226 can beused to calculate a liquid level of the chemical precursor 204 in thesource 202. The calculation of the liquid level can be made when thechemical precursor 204 is not flowing based on principles of hydrostaticpressure in a non-moving fluid using the height of the pressuretransducer 226 and the measured pressure in the feed line 210. Thisalleviates the need for any kind of a liquid level sensor in the source202 (e.g., a float inside the source 202, an optical sensor in thesource 202, etc.). Because the pressure transducer 226 is not inside thesource 202, when the dip tube system 200 is changed over from an emptysource to a full source, there is no sensor to move dip tube system 200and/or clean when the dip tube system 200 is moved. In addition, acontroller (not shown), such as a computing device, communicativelycoupled to the pressure transducer can calculate the liquid level of thechemical precursor 204 in the source 202 automatically. The controllercan issue one or more signals to a user when the calculated liquid levelreaches particular levels so the user knows to order a new source of thechemical precursor 204 when the liquid level reaches a low level, toreplace the source 202 with a new source when the liquid level reachesan empty level, or to perform any other action based on the calculatedliquid level. In this way, the source 202 does not need to betransparent or semi-transparent for the user to know how much of thechemical precursor 204 remains in the source 202.

In another example, the pressure measurement by the pressure transducer226 can be used to detect clogs in the feed line 210 upstream of thetransfer pump 222. If the feed line 210 becomes clogged anywhere betweenthe bottom of the dip tube 209 and the pressure transducer 226, the flowof the chemical precursor 104 through the feed line 210 would cease andthe pressure between the blockage and the transfer pump 222 woulddecrease. The pressure transducer 226 would detect the low pressure and,in response, could issue a signal. This signal would alert a user to theblockage much sooner than would otherwise be detected and would avoidwaste of other chemical precursors that would otherwise be dispenseduntil the blockage was detected. Another benefit of the pressuremeasurement by the pressure transducer 226 is the ability to avoidcrossovers, which can destroy a foam-in-bag system.

In another example, the pressure measurement by the pressure transducer226 can be used to detect cavitation in the feed line 210. If thechemical precursor 204 is in liquid form, the chemical precursor 204 hasa specific vapor pressure at a given temperature so that the vaporpressure is a function of temperature. Whenever a liquid pressure fallsbelow its vapor pressure, the liquid begins to boil. Cavitation occurswhen the drop below the vapor pressure is caused by suction from a pump,and cavitation can cause many problems within the feed line 210 andthroughout the pumping system. In some embodiments, if the pressuretransducer 226 detects a drop in pressure that approaches a cavitationpressure, the pumping system can shut down and/or provide a warning tothe user that cavitation may be possible. In the depicted embodiment,the temperature sensor 228 is also capable of detecting the temperaturewithin the feed line 210 upstream of the transfer pump 222. Thetemperature in the chemical precursor 204 can be used in addition to thepressure measured by the pressure transducer 226 to ensure accuracy ofthe determination that conditions are approaching cavitation.

In some embodiments described herein, the temperature of chemicalprecursors in a foam-in-bag system is controlled. Depicted in FIG. 3A isa perspective view of an embodiment of the dispenser manifolds 146 andthe dispenser 174, collectively, of the foam-in-bag system 100. Depictedin FIGS. 3B to 3F are perspective views of embodiments of the dispenser174 and portions of the dispenser manifolds 146, individually. Inparticular, FIG. 3B depicts a perspective view of an embodiment of thedispenser 174; FIG. 3C depicts a perspective view of an embodiment ofthe output block 168 _(B) of the second dispenser manifold 146 _(B);FIG. 3D depicts a perspective view of an embodiment of the output block168 _(A) of the first dispenser manifold 146 _(A); FIG. 3E depicts aperspective view of an embodiment of the input block 158 _(A) of thefirst dispenser manifold 146 _(A); and FIG. 3F depicts a perspectiveview of an embodiment of the input block 158 _(B) of the seconddispenser manifold 146 _(B).

In the embodiment depicted in FIG. 3A, the input blocks 158 are arrangedsubstantially in parallel with each other. One end of each of the inputblocks 158 (the ends to the right in FIG. 3A) includes couplingsconfigured to couple to hoses (e.g., hoses 148) for supplying chemicalprecursors to the input blocks 158. The other ends of the input blocks158 are coupled to the output blocks 168. In the depicted embodiment,the output blocks 168 are arranged substantially parallel to each otherand substantially perpendicular to the input blocks 158. Together, theinput blocks 158 and the output blocks 168 form the dispenser manifolds146. One end of each of the output blocks 168 is coupled to one of theinput blocks 158 and the other end of each of the output blocks 168 iscoupled to the dispenser 174. The first dispenser manifold 146 _(A) isconfigured to pass the first chemical precursor 104 _(A) to thedispenser 174 via the feed line 110 _(A) that passes through the inputblock 158 _(A) and the output block 168 _(A). The second dispensermanifold 146 _(B) is configured to pass the second chemical precursor104 _(B) to the dispenser 174 via the feed line 110 _(B) that passesthrough the input block 158 _(B) and the output block 168 _(B). Thedispenser 174 is configured to dispense a ratio of the first chemicalprecursor 104 _(A) and the second chemical precursor 104 _(B) such thatthe dispensed chemical precursors 104 mix to react and form foam.

In the embodiment depicted in FIG. 3B, the dispenser 174 includes themixing cartridge manifold 176, which includes the heating element 180and the temperature sensor 182. The heating element 180 is configured toheat the mixing cartridge manifold 176. In some embodiments, the heatingelement 180 is a cartridge style heating element rated in a range from60 watts to 100 watts, such as 80 watts. In one example, the heatingelement 180 is cylinder-shaped with a length of about 4 inches and adiameter of about 0.25 inches. The temperature sensor 182 is configuredto detect the temperature of the mixing cartridge manifold 176. In someembodiments, a controller (e.g., a computing device) is configured tocontrol operation of the heating element 180 based on indications fromthe temperature sensor 182 of the temperature of the mixing cartridgemanifold 176. For example, the controller may alternate between causingthe heating element 180 to be powered and causing the heating element180 to be unpowered based on fluctuations in the indications from thetemperature sensor 182 of the temperature of the mixing cartridgemanifold 176. In this way, the temperature of the mixing cartridgemanifold 176 may be kept in a desired temperature range for the firstand second chemical precursors 104 as they pass through the mixingcartridge manifold 176.

In the embodiment depicted in FIG. 3C, the output block 168 _(B)includes a portion of the feed line 110 _(B) through which the secondchemical precursor 104 _(B) is capable of flowing. The output block 168_(B) also includes the heating element 170 _(B) and the temperaturesensor 172 _(B). The heating element 170 _(B) is configured to heat theoutput block 168 _(B). In some embodiments, the heating element 170 _(B)is a cartridge style heating element rated in a range from 100 watts to200 watts, such as 150 watts. In one example, the heating element 170_(B) is cylinder-shaped with a length of about 12.125 inches and adiameter of about 0.25 inches. The temperature sensor 172 _(B) isconfigured to detect the temperature of the output block 168 _(B). Insome embodiments, a controller (e.g., a computing device) is configuredto control operation of the heating element 170 _(B) based onindications from the temperature sensor 172 _(B) of the temperature ofthe output block 168 _(B). For example, the controller may alternatebetween causing the heating element 170 to be powered and causing theheating element 170 to be unpowered based on fluctuations in theindications from the temperature sensor 172 _(B) of the temperature ofthe output block 168 _(B). In this way, the temperature of the outputblock 168 _(B) may be kept in a desired temperature range for the secondchemical precursor 104 _(B) as it passes through the output block 168_(B). The output block 168 _(B) also includes a secondary line 171B,which can be used to feed other fluid through the output block 168 _(B).

In the embodiment depicted in FIG. 3D, the output block 168 _(A)includes a portion of the feed line 110 _(A) through which the firstchemical precursor 104 _(A) is capable of flowing. The output block 168_(A) also includes the heating element 170 _(A) and the temperaturesensor 172 _(A). The heating element 170 _(A) is configured to heat theoutput block 168 _(A). In some embodiments, the heating element 170 _(A)is a cartridge style heating element rated in a range from 100 watts to200 watts, such as 150 watts. In one example, the heating element 170_(A) is cylinder-shaped with a length of about 13.25 inches and adiameter of about 0.25 inches. The temperature sensor 172 _(A) isconfigured to detect the temperature of the output block 168 _(A). Insome embodiments, a controller (e.g., a computing device) is configuredto control operation of the heating element 170 _(A) based onindications from the temperature sensor 172 _(A) of the temperature ofthe output block 168 _(A). For example, the controller may alternatebetween causing the heating element 170 _(A) to be powered and causingthe heating element 170 _(A) to be unpowered based on fluctuations inthe indications from the temperature sensor 172 _(A) of the temperatureof the output block 168 _(A). In this way, the temperature of the outputblock 168 _(A) may be kept in a desired temperature range for the secondchemical precursor 104 _(A) as it passes through the output block 168_(A). The output block 168 _(A) also includes a secondary line 171 _(A),which can be used to feed other fluid through the output block 168 _(A).In the depicted embodiment, a cleaning solution is capable of flowingthrough the secondary line 171 _(A) to the mixing cartridge manifold176. In some cases, the efficacy of the cleaning solution may improvewhen heated by the output block 168 _(A) as the cleaning solution flowsthrough the secondary line 171 _(A) and the heating element 170 _(A) iscontrolled to heat the output block 168 _(A).

In the embodiment depicted in FIG. 3E, the input block 158 _(A) includesa portion of the feed line 110 _(A) through which the first chemicalprecursor 104 _(A) is capable of flowing. The input block 158 _(A) alsoincludes the heating element 160 _(A) and the temperature sensor 162_(A). The heating element 160 _(A) is configured to heat the input block158 _(A). In some embodiments, the heating element 160 _(A) is acartridge style heating element rated in a range from 250 watts to 750watts, such as 500 watts. In one example, the heating element 160 _(A)is cylinder-shaped with a length of about 24.625 inches and a diameterof about 0.375 inches. The temperature sensor 162 _(A) is configured todetect the temperature of the input block 158 _(A). In some embodiments,a controller (e.g., a computing device) is configured to controloperation of the heating element 160 _(A) based on indications from thetemperature sensor 162 _(A) of the temperature of the input block 158_(A). For example, the controller may alternate between causing theheating element 160 _(A) to be powered and causing the heating element160 _(A) to be unpowered based on fluctuations in the indications fromthe temperature sensor 162 _(A) of the temperature of the input block158 _(A). In this way, the temperature of the input block 158 _(A) maybe kept in a desired temperature range for the first chemical precursor104 _(A) as it passes through the input block 158 _(A). The input block158 _(A) also includes the filter 166 _(A) in the portion of the feedline 110 _(A) that passes through the input block 158 _(A). In someembodiments, the filter 166 _(A) is configured to filter the firstchemical precursor 104 _(A) with a fine-pore depth filter. In somecases, the fine-pore depth filter is of a size, such as a 100-micronrating, that the filter 166 _(A) is expected to last for the life of theinput block 158 _(A) without being serviced or replaced. In someembodiments, the filter 166 _(A) is a porous high density polyethylene(HDPE) filter.

In the embodiment depicted in FIG. 3F, the input block 158 _(B) includesa portion of the feed line 110 _(B) through which the second chemicalprecursor 104 _(B) is capable of flowing. The input block 158 _(B) alsoincludes the heating element 160 _(B) and the temperature sensor 162_(B). The heating element 160 _(B) is configured to heat the input block158 _(B). In some embodiments, the heating element 160 _(B) is acartridge style heating element rated in a range from 250 watts to 750watts, such as 500 watts. In one example, the heating element 160 _(A)is cylinder-shaped with a length of about 24.625 inches and a diameterof about 0.375 inches. The temperature sensor 162 _(B) is configured todetect the temperature of the input block 158 _(B). In some embodiments,a controller (e.g., a computing device) is configured to controloperation of the heating element 160 _(B) based on indications from thetemperature sensor 162 _(A) of the temperature of the input block 158_(A). For example, the controller may alternate between causing theheating element 160 _(A) to be powered and causing the heating element160 _(A) to be unpowered based on fluctuations in the indications fromthe temperature sensor 162 _(A) of the temperature of the input block158 _(B). In this way, the temperature of the input block 158 _(B) maybe kept in a desired temperature range for the second chemical precursor104 _(B) as it passes through the input block 158 _(B). The input block158 _(B) also includes the filter 166 _(B) in the portion of the feedline 110 _(B) that passes through the input block 158 _(B). In someembodiments, the filter 166 _(B) is configured to filter the secondchemical precursor 104 _(B) with a fine-pore depth filter. In somecases, the fine-pore depth filter is of a size that the filter 166 _(B)is expected to last for the life of the input block 158 _(B) withoutbeing serviced or replaced.

When the dispenser manifolds 146 and the dispenser 174 are arranged inthe embodiment shown in FIG. 3A, the chemical precursors 104 areconfigured to be heated independently as they flow toward the dispenser174 and then are both heated by the mixing cartridge manifold 176. Inother words, the dispenser manifolds 146 independently heat the firstchemical precursor 104 _(A) and the second chemical precursor 104 _(B)as the chemical precursors flow toward the dispenser 174 and then themixing cartridge manifold 176 heats the chemical precursors 104 togetheras they flow in the dispenser 174. In the particular embodiment depictedin FIG. 3A, there are five discrete, but coupled, heating zones: (1) theinput block 158 _(A) is a heating zone for the first chemical precursor104 _(A), (2) the output block 168 _(A) is a heating zone for the firstchemical precursor 104 _(A), (3) the input block 158 _(B) is a heatingzone for the second chemical precursor 104 _(B), (4) the output block168 _(B) is a heating zone for the second chemical precursor 104 _(B),and (5) the mixing cartridge manifold 176 in the dispenser 174 is aheating zone for both of the first and second chemical precursors 104_(A) and 104 _(B).

Having multiple heating zones for the chemical precursors 104 beforethey are dispensed by the dispenser provides a number of advantages. Inone example, the chemical precursors 104 can be maintained with a rangeof temperatures that improve flowability of the chemical precursors 104,increase efficacy of the chemical precursors 104 when they are mixedtogether to form foam, and/or reduce the likelihood of crystal formationin the chemical precursors 104. In another example, the multiple heatingzones reduce variations in the temperature of the chemical precursors104, such as reducing the magnitude and frequency of temperature dipsand spikes. In another example, the heating zones maintain the chemicalprecursors 104 in a desired temperature range during periods when thefoam-in-bag system is idle, whether for short or long periods of idle.In another example, the thermal mass of the input and output blocks 158and 168 of the dispenser manifolds 146 and the thermal mass of themixing cartridge manifold 176 may help to minimize fluctuations in thetemperature of the chemical precursors 104.

The ability to heat the chemical precursors 104 before the dispenser 174can be highly beneficial. For example, in the dispenser manifolds 146can be controlled independently so that the chemical precursors 104 aremaintained at different temperatures. Because the chemical precursors104 are different, the temperatures at which they are most effectivetemperatures may also be different. The ability to control thetemperature of the dispenser manifolds 146 independently allows thechemical precursors 104 to be held at different temperatures that are ator near their most effective temperatures. Even though both of thechemical precursors subsequently pass into the mixing cartridge manifold176 where they cannot be heated independently, the mixing cartridgemanifold 176 can hold a small volume of the chemical precursors 104 inorder to minimize the change in temperature of the chemical precursors104 in the mixing cartridge manifold 176. In addition, the targettemperatures in the dispenser manifolds 146 can be set based at least onany change of temperature that may occur in the mixing cartridgemanifold 176 so that the chemical precursors 104 are at or near adesired dispensing temperature after the effect of the mixing cartridgemanifold 176 on the chemical precursors 104.

In some embodiments, the each of the multiple heating zones iscontrolled independently. For example, each heaving zone may atemperature sensor to measure the temperature in that zone and acontroller to control the heating element in that zone. In someembodiments, each of the heating zones includes a controller, such as aprinted circuit board with circuitry configured to control the heatingelement in that zone to cause the temperature in the heating zone to bemaintained at or near a specific temperature or within a particularrange of temperatures. In a specific example, each of the input block158, the output blocks 168, and the mixing cartridge manifold 176includes a printed circuit board with circuitry configured to controlthe respective heating element in that zone (e.g., one of the heatingelements 160, one of the heating elements 170, or the heating element180) based on indications from the temperature sensor in that zone(e.g., one of the temperature sensors 162, one of the temperaturesensors 172, or the temperature sensor 182). In some embodiments, thecontrollers are configured to alternate between causing the heatingelement to be powered and causing the heating element to be unpoweredbased on fluctuations in the indications from the temperature sensor. Insome examples, the controllers are capable of maintaining thetemperature in the temperature zone within 1° F. of a targettemperature, within 2° F. of a target temperature, or within 5° F. of atarget temperature.

In some embodiments, in addition to the heating of the chemicalprecursors 104 provided in the dispenser manifolds 146 and the mixingcartridge manifold 176, the chemical precursors 104 can be heatedupstream of the dispenser manifolds 146. As noted above with respect toFIG. 1B, the hoses 148 can include heating elements 150 to heat thechemical precursors 104 as they pass through the hoses 148. In someexamples, the heating elements 150 are heater wires, such as coilednichrome, rated to 1,750 watts with a 25-ohm resistance. Heating thechemical precursors 104 in the hoses 148 can reduce the difference intemperature between the chemical precursors 104 as they enter thedispenser manifolds 146 and the controlled temperature of the inputblocks 158 in the dispenser manifolds 146. As can be seen in FIG. 1B,the hoses 148 can include a temperature sensor (e.g. temperature sensor152 _(A)) and controlled in a feedback manner similar to the heatingzones above, or the hoses 148 can be uncontrolled and lack a temperaturesensor (e.g., as in the case of the hose 148 _(B)). In the depictedembodiment, the heating elements 150 are in direct contact with thechemical precursors 104 as they pass through the hoses 148.

As discussed above, the mixing cartridge 178 is configured to beselectively controlled to dispense specific amounts of the first andsecond chemical precursors 104 _(A) and 104 _(B) into formed bags.Depicted in FIGS. 4A to 4C are perspective and cross-sectionalperspective views of an embodiment of the mixing cartridge 178. Morespecifically, FIG. 4A depicts a perspective view of the mixing cartridge178 in a closed orientation, FIG. 4B depicts a cross-sectionalperspective view of the mixing cartridge 178 in the closed orientation,and FIG. 4C depicts a cross-sectional perspective view of the mixingcartridge 178 in an open orientation.

The mixing cartridge 178 includes a valving rod 186 that can slide in anaxial direction to open and close the mixing cartridge 178. The mixingcartridge 178 includes an outlet 188 through which dispensed chemicalprecursors can exit the mixing cartridge 178. The mixing cartridge 178also includes a mixing chamber 190 where chemical precursors can beginmixing before the chemical precursors are dispensed out of the outlet188. The mixing cartridge 178 also includes inlets 192 configured topermit chemical precursors and/or cleaning solution to flow into themixing cartridge 178. In some embodiments, the inlets 192 that receivechemical precursors are configured to direct the chemical precursorsinto the mixing chamber 190. In some embodiments, the walls of themixing chamber 190 are made of a material that is nonreactive with manychemicals, such as polytetrafluoroethylene (PFTE), which is distributedunder the trade name of TEFLON by The Chemours Company of Wilmington,Del.

As can be seen in FIGS. 4A and 4B, when the mixing cartridge 178 is inthe closed orientation, the valving rod 186 extends through the mixingcartridge 178 and blocks the outlet 188. When the mixing cartridge 178is in the closed orientation, the valving rod 186 also blocks the mixingchamber 190 and the path from the inlets 192 into the mixing chamber190. In this way, when the mixing cartridge 178 is in the closedorientation, the valving rod 186 blocks flow of chemical precursors fromthe inlet 192 into the mixing chamber 190, flow of chemical precursorsthrough the mixing chamber 190, and flow of chemical precursors from themixing chamber 190 out of the outlet 188.

As can been seen in FIG. 4C, when the mixing cartridge 178 is in theopen orientation, the valving rod 186 is retracted so that the valvingrod 186 does not block the outlet 188. When the mixing cartridge 178 isin the open orientation, the valving rod 186 does not block the pathfrom the inlets 192 into the mixing chamber 190 and the valving rod 186does not block the mixing chamber 190 itself. In this way, when themixing cartridge 178 is in the open orientation, the position of thevalving rod 186 permits chemical precursor to flow through the inlets192 into the mixing chamber 190, through the mixing chamber 190, andfrom the mixing chamber 190 out of the outlet 188.

Depicted in FIGS. 4D and 4E is an embodiment of a dispenser drivemechanism 300 configured to selectively open and close the mixingcartridge 178 of the foam-in-bag system 100. More specifically, FIG. 4Ddepicts a front view of the dispenser drive mechanism 300 with themixing cartridge 178 in the closed position, FIG. 4E depicts a frontview of the dispenser drive mechanism 300 with the mixing cartridge 178in the open position, and FIG. 4F depicts a perspective view of thedispenser drive mechanism 300 with the mixing cartridge 178 in theclosed position.

The dispenser drive mechanism 300 is configured to raise and lower thevalving rod 186 to open and close the mixing cartridge 178. To open themixing cartridge 178, the valving rod 186 is retracted through themixing chamber 190 (e.g., moved upward from the position of the valvingrod 186 shown in the view shown in FIG. 4D to the position of thevalving rod 186 shown in the view shown in 4E). In some embodiments, thefull distance traversed by the valving rod 186 is less than or equal toabout 1 inch, such as a distance of about 0.875 inches. This allows theend of the valving rod 186 to clear the outlet 188 and the opening ofthe inlets 192, which permits the chemical precursors to flow into themixing chamber 190. The mixing of the chemical precursors may result inthe production of a reactant material, such as urethane foam. To closethe mixing cartridge 178, the valving rod 186 is driven downward, backthrough the mixing chamber 190 by the same distance (e.g., less than orequal to about 1 inch). This motion of the valving rod 186 closes offthe inlets 192, shutting the flow of chemical precursors into the mixingchamber 190 and the flow of foam out of the outlet 188.

In some embodiments, the motion of the valving rod 186 is a simplelinear motion. However, large forces may be required to move the valvingrod 186 against the compressive, sealing force of the mixing chamber 190(e.g., the PFTE walls of the mixing chamber 190) and against the bondingfrom urethane foam residue between the inner surface of the mixingchamber 190 and the outer surface of the valving rod 186. In some cases,the urethane foam residue acts as a strong bonding agent which isdesired to be cleared out of the mixing chamber 190 each time thevalving rod 186 is extended. In addition to overcoming the forces actingagainst the movement of the valving rod 196, one possible object of thedispenser drive mechanism 300 is to provide a consistent opening timeand closing time of the mixing cartridge 178. In some cases, it isdesirable for the dispenser drive mechanism 300 is to provide aconsistent opening time and closing time of the mixing cartridge 178even if the mixing cartridge 178 has been used heavily and urethanebonds have formed between the outer surface of the valving rod 186 andthe inner surface of the mixing chamber 190. In some embodiments,opening and closing times are less than or equal to about 200milliseconds (ms). For example, opening and closing times may be in arange between about 150 ms and about 200 ms.

In typical foam-in-bag systems, bags are formed from film and thechemical precursors are dispensed into the film bag. The film bags aretypically formed by passing one ply of the film in front of thedispenser (e.g., in front of the mixing cartridge 178) and another plyof the film in back of the dispenser (e.g., in back of the mixingcartridge 178). Because the film passes on either side of the dispenser,there is little space available for the components associated with thedispenser, such as dispenser drive mechanism that opens and closes thedispenser. This limited space presents a challenge to providing adispenser drive mechanism that is capable of generating the requiredforces and power in the space available between the plies of film. Inaddition, the limited amount of space may not allow for the dispenserdrive mechanism to be aligned axially with the valving rod of thedispenser (e.g., the valving rod 186 of the mixing cartridge 178).

Depicted in FIGS. 4D to 4F are views of an embodiment of the dispenserdrive mechanism 300 that is capable of driving the valving rod 186 toopen and close the mixing cartridge 178. More specifically, FIG. 4Ddepicts a front view of the dispenser drive mechanism 300 with themixing cartridge 178 in the closed orientation, FIG. 4E depicts a frontview of the dispenser drive mechanism 300 with the mixing cartridge 178in the open orientation, and FIG. 4F depicts a perspective view of thedispenser drive mechanism 300 with the mixing cartridge 178 in theclosed orientation.

The dispenser drive mechanism 300 includes a drive motor 302. The drivemotor 302 is configured to impart a driving force. In some embodiments,the drive motor 302 is a motor with full servo capability. In oneembodiment, the drive motor 302 is a CPM-SDSK-2341P-ELN motordistributed by Teknic, Inc. of Victor, N.Y. In some embodiments, thedrive motor 302 is a brushless DC motor with neodymium magnets, abuilt-in encoder, and a built-in controller. In some embodiments, thedrive motor 302 runs on 75 VDC with a peak torque of over 400ounce-inches (over 2.82 newton-meters) and a top speed of 4,000 rpm.

The dispenser drive mechanism 300 also includes a cam plate 304 coupledto the drive motor 302. The cam plate 304 includes a cam slot 306. Inthe depicted embodiment, the cam plate 304 is configured to betranslated by the driving force provided drive motor 302. The dispenserdrive mechanism 300 includes rollers 308 configured to support the camplate 304 as it is translated by the drive motor 302. While the depictedembodiment includes rollers 308 to support the cam plate 304, thedispenser drive mechanism 300 could also include any other cam platesupport, such as bearings, slotted brackets, or any other mechanismconfigured to support and guide the cam plate 304 as it translates.

The dispenser drive mechanism 300 also includes a valving rod connector310. One end of the valving rod connector 310 is configured to becoupled to the valving rod 186. The valving rod connector 310 alsoincludes a pin 312 that passes through and engages the cam slot 306. Insome embodiments, the pin 312 is a roller pin. The pin 312 is coupled tothe valving rod connector 310 such that a force imparted on the pin 312by the cam slot 306 results in a linear movement of the valving rodconnector 310. When the valving rod connector 310 is coupled to thevalving rod 186, the linear movement of the valving rod connector 310causes a corresponding linear movement of the valving rod 186. As can beseen in FIG. 4F, the dispenser drive mechanism 300 can include linearbearings 314 configured to support and guide the valving rod connector310 as it translates.

In the depicted embodiment, the dispenser drive mechanism 300 includes adrive coupling assembly 316. The drive coupling assembly 316 is coupledto the drive motor 302 and to the cam plate 304. The drive couplingassembly 316 is configured to convert rotational motion of the drivemotor 302 into linear motion of the cam plate 304. In the depictedembodiment, the drive coupling assembly 316 includes a drive screw 318that is coupled to a shaft of the drive motor 302. The drive motor 302is capable of turning the drive screw 318 in two rotational directions(e.g., clockwise and counterclockwise). In some embodiments, the drivescrew 318 has a diameter of about 0.5 inches with external threadshaving a 0.5-inch pitch. The drive coupling assembly 316 also includes anut 320 configured to engage with the drive screw 318. In the depictedembodiment, the nut 320 has internal threads that mate with the externalthreads of the drive screw 318. If the nut 320 is prevented fromrotating, the rotation of the drive screw 318 will result in a linearmotion of the nut 320 either toward or away from the cam plate 304,depending on the direction of rotation of the drive screw 318. The drivecoupling assembly 316 also includes a nut extender 322. The nut extender322 is coupled to the nut 320 and coupled to the cam plate 304. In thedepicted embodiment, the nut extender 322 is coupled to the cam plate304 via a pin. The linear motion of the nut 320 causes a correspondinglinear motion of the nut extender 322, which in turn causes acorresponding linear motion of the cam plate 304. While the embodimentof the drive coupling assembly 316 depicted in FIGS. 4D to 4F is arotational-to-linear drive coupling assembly, it will be apparent thatany other coupling mechanism may be used to convert the motion of thedrive motor 302 into a corresponding motion of the cam plate 304.

The dispenser drive mechanism 300 is configured to open the mixingcartridge 178 by retracting the valving rod 186. To retract the valvingrod 186, the drive motor 302 operates to provide a rotational drivingforce in one rotational direction. The drive coupling assembly 316transforms the rotational driving force into a linear translationalforce, causing the cam plate 304 to translate linearly. In the depictedembodiment, the cam plate 304 translates from the location shown in FIG.4D to the left toward the location shown in FIG. 4E. As the cam plate304 translates, the cam slot 306 imparts a force on the pin 312 to causethe valving rod connector 310 to translate linearly. In the depictedembodiment, the linear translation of the cam plate 304 is substantiallyperpendicular to the linear translation of the valving rod connector310. As the cam plate 304 translates from the location shown in FIG. 4Dto the left toward the location shown in FIG. 4E, the valving rodconnector 310 translates from the location shown in FIG. 4D upwardtoward the location shown in FIG. 4E. The upward movement of the valvingrod connector 310 causes the valving rod 186 to also move upward,withdrawing the valving rod 186 from the outlet 188, the mixing chamber190, and the inlets 192 of the mixing cartridge 178.

As the cam plate 304 translates, the cam plate 304 is supported by therollers 308. In some embodiments, some of the rollers 308 are flat-facedrollers configured to contact a flat surface of the cam plate 304. Inthe depicted embodiment, the lower two rollers 308 are flat-facesrollers configured to engage a flat face on the bottom of the cam plate304. In some embodiments, some of the rollers 308 are grooved rollersconfigured to contact a V-shaped surface of the cam plate 304. In thedepicted embodiment, the upper two rollers 308 are grooved rollersconfigured to engage a V-shaped upper surface of the cam plate 304. Itwill be apparent that the upper surface of the cam plate 304 could begrooved and the rollers could be V-shaped to achieve the samearrangement. In some cases, the engagement of the V-shaped rollers 308or cam plate 304 engage the grooved cam plate 304 or rollers 308 toreduce or eliminate jerk in the motion of the cam plate 304. The shapeof the groove may also aid in transferring a greater percentage of thedrive force to the valving rod 186 at the start of the opening stroke.In some conditions, the start of the opening stroke is when the bondingfrom the urethane foam remnants is strongest. This increases thelikelihood that the mixing cartridge 178 will open, regardless of theamount of adhered urethane foam remnants in the mixing chamber 190 ofthe dispenser.

The dispenser drive mechanism 300 is configured to close the mixingcartridge 178 by extending the valving rod 186. To extend the valvingrod 186, the drive motor 302 operates to provide a rotational drivingforce in the other rotational direction. The drive coupling assembly 316transforms the rotational driving force into a linear translationalforce, causing the cam plate 304 to translate linearly. In the depictedembodiment, the cam plate 304 translates from the location shown in FIG.4E to the right toward the location shown in FIG. 4D. As the cam plate304 translates, the cam slot 306 imparts a force on the pin 312 to causethe valving rod connector 310 to translate linearly. In the depictedembodiment, the linear translation of the cam plate 304 is substantiallyperpendicular to the linear translation of the valving rod connector310. As the cam plate 304 translates from the location shown in FIG. 4Eto the right toward the location shown in FIG. 4D, the valving rodconnector 310 translates from the location shown in FIG. 4E downwardtoward the location shown in FIG. 4D. The downward movement of thevalving rod connector 310 causes the valving rod 186 to also movedownward, extending the valving rod 186 through the mixing chamber 190to close the inlets 192 and the outlet 188.

One benefit to the dispenser drive mechanism 300 depicted in FIGS. 4D to4F is that the cam plate 304 is driven linearly in a directionsubstantially perpendicular to the direction of the movement of thevalving rod 186. This arrangement allows the drive motor 302 and the camplate 304 to be arranged perpendicularly to the direction of thedispenser. In the event that the foam-in-bag system feeds the plies offilm in the direction of the dispenser 186, the drive motor 302 and thecam plate 304 do not need to be arranged in the same direction of thefeeding of the film plies. This allows the path of the film plies to beshorter than if the drive motor 302 and the cam plate 304 were arrangedin the same direction of the feeding of the film plies. This arrangementalso allows some of the components (e.g., the drive motor 302) to belocated outside of the plies of film and away from the chemicalprecursors, the resultant foam, and any cleaning solution used to cleanthe mixing cartridge 178. In some embodiments, the dispenser drivemechanism 300 is capable of generating peak loads of more than 1,000 lbsduring a stroke that takes less than about 200 ms (e.g., about 150 ms).The cam plate 304 is capable of transferring this amount of force in asubstantially perpendicular direction to cause most of the force to betransferred to the valving rod 186.

Many foam-in-bag systems are capable of forming a bag from a film web,dispensing chemical precursors into the formed bag, and then closing thebag before the chemical precursors fully react an expand to their fullvolume. In some embodiments, the film web is provided on a roll wherethe film is folded in half longitudinally when it is on the roll. Thefoam-in-bag system feeds the film such that the fold in the film becomesone of the longitudinal sides. The foam-in-bag system also seals thelongitudinal edges of the film opposite the fold to form the otherlongitudinal side of the bag. The ply of film on one side of the foldforms the front of the bag and the ply of film on the other side of thefold forms the back of the bag. The foam-in-bag system forms transverseseals in the film to form the bottom and the top of the bag and cuts thefilm outside of the bottom and the top to separate the bag from the filmweb. Examples of the above-described foam-in-bag systems and a varietyof other foam-in-bag systems are provided in U.S. Pat. Nos. 4,854,109;4,938,007; 5,139,151; 5,376,219; 5,575,435; 5,679,208; 5,727,370;6,131,375; 6,178,725; and 6,472,638; the contents of all of which arehereby incorporated by reference in their entirety.

Film webs for use in foam-in-bag systems are typically provided in aretypically supplied on a roll of film. The roll typically includes acylindrical core (e.g., a core made of a paper-based material) with thefilm web wound around the cylindrical core. To use the film, the core ofthe roll is typically mounted on a spindle or other structure where thecore is able to rotate as the film web is unrolled by the foam-in-bagsystem. When the film web is depleted, the core is removed from thefoam-in-bag system and discarded, and a new roll of film is loaded ontothe foam-in-bag system. Because the core is merely discarded after use,it is advantageous for the core to be as inexpensive as possible toreduce the overall costs associated with the film.

One difficulty with the usability of foam-in-bag systems is the time andeffort needed to load a roll of film on the foam-in-bag system for thefoam-in-bag system to be able to use the film. For example, when a rollof film has a full length of film would around the core, the roll canhave a weight that makes it cumbersome or dangerous for one person tohandle. This difficulty in handling may result in rolls of film fallingor otherwise being damaged in a way that deforms the core. This problemis exacerbated when cores are made from cheaper materials (e.g., an ineffort to reduce the cost of the core), which are more easily deformed.As used herein, a deformed core refers to a core that is not perfectlycylindrical, and includes dented cores, crushed cores, twisted cores, orany other form of a core that is not perfectly cylindrical. When thecore is deformed, it can be difficult for a user to slide the roll overthe spindle or other support structure that holds the roll. In addition,rolls of film may have different widths depending on the size of bagsthat are intended to be made with the film, and it can be difficult fora user to adjust the spindle or other support structure on thefoam-in-bag system to accommodate the different size width while tryingto handle a full roll of film. This adjustment of the spindle or othersupport structure typically requires the use of tools (e.g.,screwdrivers, ratchets, etc.) that make the adjustment even moredifficult for the user.

One embodiment of a roll 400 of film web on the foam-in-bag system 100is depicted in FIG. 5A. In that embodiment, the roll 400 has been placedon a spindle system 402. For convenience, the roll 400 has been shown inFIG. 5A as transparent so that the spindle system 402 is visible;however, in many embodiments, the roll 400 is not transparent. Thespindle system 402 includes a rod 404. In the depicted embodiment, therod 404 is fixedly coupled to a housing 194 of the foam-in-bag system100 such that the rod 404 does not rotate or translate with respect tothe housing 194. The rod 404 is cantilevered out from the housing 194with a proximal end of the rod 404 located near the housing 194 and adistal end of the rod 404 located away from the housing 194. The rod 404is cylindrical in shape with an outer diameter that is less than theinner diameter of the core of the roll 400.

The spindle system 402 includes a proximal wing 406 and a distal wing408 that are configured to contact the inner diameter of the core of theroll 400. Each of the proximal wing 406 and the distal wing 408 isrotatably coupled to the rod 404. For example, each of the proximal wing406 and the distal wing 408 may have a bore through which the rod 404passes that permits the each of the proximal wing 406 and the distalwing 408 to rotate around the rod 404. In the depicted embodiment, theproximal wing 406 is operatively coupled to a motor (not shown) insideof the housing 194 and the motor is capable of selectively rotating theproximal wing 406 around the rod 404. In addition, the distal wing 408is not coupled to the motor so that the distal wing 408 is capable ofrotating around the rod 404 independently of the operation of the motor.

The proximal wing 406 and the distal wing 408 are configured to contactthe inner diameter of the core of the roll 400 at diametrically-opposedlocations on the inner surface of the core. The proximal wing 406includes contact surfaces 410 and the distal wing 408 includes contactsurfaces 412. When the proximal wing 406 and the distal wing 408 are onthe rod 404, the contact surfaces 410 and 410 are spaced away from therod 404 such that the contact surfaces 410 contact diametrically-opposedlocations on the inner surface of the core at the proximal side of theroll 400 and the contact surfaces 412 contact diametrically-opposedlocations on the inner surface of the core at the distal side of theroll 400. In some embodiments, the contact surfaces 410 and 410 arecontoured surfaces based on an expected contour of the inner surface ofthe core of the roll 400. Having contoured surfaces may increase thepercentage of the surface area of the contact surfaces 410 and 410 thatis in contact with the core of the roll 400.

The proximal wing 406 also includes non-contact surfaces 414 and thedistal wing 408 includes non-contact surfaces 416. The non-contactsurfaces 414 span between the contact surfaces 410 and the non-contactsurfaces 416 span between the contact surfaces 412. When the core of theroll 400 has a cylindrical shape and the roll 400 is on the proximalwing 406 and the distal wing 408, the non-contact surfaces 414 and 416do not contact the core of the roll 400. However, as noted above, thecores in rolls of film can be damaged and deformed during shipping orhandling. If the core of the roll 400 has a deformity, the roll 400 canbe positioned with respect to the proximal wing 406 such that anydeformities in the proximal end of the roll 400 at the proximal wing 406are not contacted by the contact surfaces 410 of the proximal wing 406.In this way, the non-contact surfaces 414 accommodate deformities in theproximal end of the core of the roll 400 while the proximal wing 406still contacts the core at the contact surfaces 410. Similarly, when theroll 400 can be positioned with respect to the distal wing 408 such thatany deformities in the distal end of the roll 400 at the distal wing 408are not contacted by the contact surfaces 412 of the distal wing 408. Inthis way, the non-contact surfaces 416 accommodate deformities in thedistal end of the core of the roll 400 while the distal wing 408 stillcontacts the core at the contact surfaces 412.

As noted above, in some embodiments, the proximal wing 406 isoperatively coupled to a motor that controls the rotational position ofthe proximal wing 406 with respect to the rod 404 and the distal wing408 is capable of rotating freely on the rod 404. In one embodiment of aprocess of loading the roll 400 on the spindle system 402, the roll 400is slid over the rod 404 from the distal end of the rod 404 to theproximal end of the rod 404. As the roll 400 is slid over the rod 404,the roll 400 is rotated so that any deformities on the proximal side ofthe roll 400 are not aligned with the contact surfaces 410 of theproximal wing 406. The distal wing 408 is also rotated so that anydeformities on the distal side of the roll 400 are not aligned with thecontact surfaces 412 of the distal wing 408. In this way, the proximalwing 406 and the distal wing 408 are able to hold the roll 400 despiteany deformities in the core of the roll 400. It will be understood thatthe proximal wing 406 and the distal wing 408 are able to hold the roll400 regardless of whether the proximal wing 406 and the distal wing 408are aligned with each other. In other words, the non-contact surfaces414 of the proximal wing 406 either be parallel or non-parallel to thenon-contact surfaces 416 of the distal wing 408 for the spindle system402 to support the roll 400. An example of the spindle system 402 withthe proximal wing 406 and the distal wing 408 not aligned with eachother is depicted in FIG. 5B.

In some embodiments, the foam-in-bag system 100 is configured toactively unwind the film from the roll 400. As used herein, “active”unwinding refers to forced and/or controlled rotation of a roll of filmto cause the film to be unwound from the roll, whereas “passive”unwinding refers to a roll rotating in response to the film being pulledand/or withdrawn from the roll. When the roll 400 is on the proximalwing 406 and the distal wing 408, core of the roll 400 is arranged withrespect to the contact surfaces 410 and 412 so that rotation of the roll400 causes rotation of the proximal wing 406 and the distal wing 408about the rod 404 and rotation of the proximal wing 406 and the distalwing 408 about the rod 404 causes rotation of the roll 400. In theembodiments where the proximal wing 406 is operatively coupled to amotor in the housing, operation of the motor drives rotation of theproximal wing 406 about the rod 404, which causes rotation of the roll400. The rotation of the roll 400 then causes rotation of the distalwing 408 about the rod 404. In this way, the foam-in-bag system 100 isable to actively unwind film from the roll 400 by driving and/orcontrolling the motor to rotate the proximal wing 406.

In some embodiments, it may be desirable for one or both of the proximalwing 406 and the distal wing 408 to be engaged to the core of the roll400 by more than the friction between the contact surfaces 410 and 412and the inner diameter of the core. In some embodiments, contactsurfaces of wings may include an engagement device to increase thefriction between the wing and the core of a roll beyond the fiction fromthe contact between the contact surfaces and the core. In the embodimentdepicted in FIG. 5A and in greater detail in FIGS. 5C and 5D, thecontact surfaces 410 include engagement devices 418. The engagementdevices 418 are configured to engage the core of the roll 400 and todecrease the possibility of the core of the roll 400 moving with respectto the contact surfaces 410.

In the particular embodiment depicted in FIGS. 5A, 5C, and 5D, theengagement devices 418 are biased away from the axis of rotation of theproximal wing 406 into the inner diameter of the core of the roll 400.The engagement devices 418 are biased by biasing mechanisms 420 outwardaway from the axis of rotation of the proximal wing 406. In the depictedembodiment, the biasing mechanisms 420 are compression springs. In otherembodiments, the biasing mechanisms 420 may be any other type of springor any other mechanisms capable of biasing the engagement devices 418.The movement of the engagement devices 418 is restricted by pins 422 inthe proximal wing 406, that limit how far outwardly the biasingmechanisms 420 can move the engagement devices 418 away from the axis ofrotation and how far inwardly the engagement devices 418 can be forcedinwardly toward the axis of rotation. When the roll 400 is not locatedon the proximal wing 406 (as is shown in FIG. 5D), the biasingmechanisms 420 are able to force the biasing mechanisms 420 outwardly asfar as the pins 422 permit. When the roll is located on the proximalwing 406 (as is shown in FIG. 5C), the core of the roll 400 pushes backon the engagement devices 418 so that the engagement devices 418 are incontact with the core and the engagement devices 418 are biased intocore by the biasing mechanisms 420.

As is discussed in greater detail below, the foam-in-bag system 100 iscapable of using film rolls of different widths. The embodiment of thespindle system 402 depicted in FIG. 5A also includes a number offeatures for convenience in adjusting the spindle system 402 toaccommodate different widths of rolls. These features may also reducethe amount of time and/or labor to remove components of the spindlesystem 402 for servicing of the foam-in-bag system 100 and/or thespindle system 402.

The spindle system 402 includes an end cap 424 located on the distal endof the rod 404. The end cap 424 is spherical in the depicted embodiment,but could be in the form of a disc, a cube, a rectangular prism, or anyother shape. The end cap 424 is configured to prevent the distal wing408 from unintentionally sliding off the distal end of the rod 404. Insome embodiments, the end cap 424 is releasably coupled to the rod 404.In one example, the rod 404 includes a threaded stud extending axiallyfrom the distal end of the rod 404 and the end cap 424 includes athreaded bore that is configured to engage the threaded stud on thedistal end of the rod 404. The end cap 424 can be removed duringservicing of the foam-in-bag system 100 to permit the distal wing 408and the proximal wing 406 to be removed from the rod 404.

The spindle system 402 also includes a distal ring clamp 426. The distalring clamp 426 is releasably clampable to the rod 404. The distal ringclamp 426 is configured to prevent the distal wing 408 from slidingtoward the proximal end of the rod 404. In some embodiments, the distalring clamp 426 can be clamped and unclamped without the use of tools. Inthe instance shown in FIG. 5A, the distal ring clamp 426 is clamped tothe rod 404 such that the distal wing 408 is between the end cap 424 andthe distal ring clamp 426. In this position, the distal wing 408 issubstantially as far from the proximal wing 406 as the end cap 424 willpermit. In other instances, the roll 400 may be not as wide as shown inFIG. 5A. In those instances, the distal wing 408 may need to be closerto the proximal wing 406 for the roll 400 to fit on the distal wing 408and the proximal wing 406. To accommodate this positioning, a user mayunclamp the distal ring clamp 426, move the distal ring clamp 426 closerto the proximal wing 406, and then clamp the distal ring clamp 426 onthe rod 404. This repositioning of the distal ring clamp 426 permits thedistal wing 408 to move closer to the proximal wing 406 to accommodate anarrower roll of film. The distal ring clamp 426 can be unclamped andremoved during servicing of the foam-in-bag system 100 to permit thedistal wing 408 and the proximal wing 406 to be removed from the rod404.

The spindle system 402 also includes a proximal ring clamp 428. Theproximal ring clamp 428 is releasably clampable to the rod 404. Theproximal ring clamp 428 is configured to prevent the proximal wing 406from sliding toward the distal end of the rod 404 and to keep theproximal wing 406 operatively coupled to the motor inside the housing194. In some embodiments, the proximal ring clamp 428 can be clamped andunclamped without the use of tools. The proximal ring clamp 428 can beunclamped and removed during servicing of the foam-in-bag system 100 topermit the proximal wing 406 to be removed from the rod 404. Coupled tothe proximal ring clamp 428 is a roll guide 430. The roll guide 430 islocated around the rod 404. In the depicted embodiment, the roll guide430 is conical with the distal end of the roll guide 430 having adiameter that is less than a diameter of the proximal end of the rollguide 430. As the roll 400 is loaded onto the spindle system 402, theproximal end of the roll 400 contacts the roll guide 430 near the distalend of the roll guide 430 and the roll guide 430 guides the roll towardsaxial alignment with the proximal wing 406 as the roll 400 continues tobe moved toward the proximal wing 406.

As noted above, the depicted embodiment of the proximal wing 406includes engagement devices 418 on the contact surfaces 410. Theengagement devices 418 are configured to engage the inner surface of thecore of the roll 400 and to deter rotation of the roll 400 with respectto the proximal wing 406. While the engagement devices 418 may deterrelative rotation of the roll 400 and the proximal wing 406, the contactsurfaces 410 and 412 and the engagement devices 418 may not sufficientlydeter axial translation of the roll 400 toward the distal end of the rod404. In the depicted embodiment, one of the contact surfaces 412 of thedistal wing 408 includes a releasable clip 432. When the roll 400 isloaded on the spindle system 402, the releasable clip 432 is configuredto contact the distal end of the roll 400 to deter axial movement of theroll 400 towards the distal end of the rod 404. In some embodiments, thereleasable clip 432 is contoured to automatically retract as the roll400 is loaded on the spindle system 402 and to extend into the positionshown in FIG. 5A after the roll 400 is loaded on the spindle system 402.

As noted above, the foam-in-bag system 100 can accommodate differentwidths of the roll 400. Examples of different widths of the roll 400 onthe foam-in-bag system 100 are shown in FIGS. 6A to 6D. Morespecifically, FIGS. 6A and 6B depict front and rear perspective views,respectively, of the foam-in-bag system 100 arranged to accommodate awide roll and FIGS. 6C and 6D depict front and rear perspective views,respectively, of the foam-in-bag system 100 arranged to accommodate anarrow roll. The foam-in-bag system 100 includes a front upper cover 510and a front lower cover 512 that are shown in a servicing orientation inFIGS. 6A and 6C. During ordinary operation, the front upper and lowercovers 510 and 512 are typically closed to prevent interference with theoperation of the foam-in-bag system 100 and to improve user safety.However, in the servicing orientation shown in FIGS. 6A and 6C, a usercan view and change components of the foam-in-bag system 100 (e.g.,change positions of the components, replace components, etc.).

The foam-in-bag system 100 is configured to form bags from filmwithdrawn from the roll 400. In some embodiments, the film includes aply of film that has been longitudinally folded so that the longitudinalfold is located at the distal side of the roll 400 and the twolongitudinal edges are located at the proximal side of the roll 400. Inthe depicted embodiment, the film is fed from the roll 400 over atensioner (e.g., a dancer bar, a fixed bar, etc.) and then downward pastthe dispenser 174. The longitudinal edges at the proximal side of thefilm are separated before the film passes the dispenser 174 so that oneside of the film passes in front of the dispenser 174 and the other sideof the film passes behind the dispenser 174. As will be described ingreater detail below, the foam-in-bag system 100 creates a longitudinalseam in the open sides of the film after the film has passed thedispenser 174, the foam-in-bag system 100 creates a transverse seal inthe film to form a bottom of the bag, and the dispenser 174 dispenseschemical precursors into the film which foam up to form foam in a bagcreated from the film. The foam-in-bag system 100 creates anothertransverse seam in the film to form the top of the bag. The film and itspath are not depicted in FIGS. 6A to 6D so that components of thefoam-in-bag system 100 are visible.

The foam-in-bag system 100 includes a proximal drive roller assembly 516and a distal drive roller assembly 518. The proximal drive rollerassembly 516 includes a driven roller 520 and the distal drive rollerassembly 518 includes a driven roller 522. The driven rollers 520 and522 are configured to be driven by a motor (not shown) to feed the film.In the depicted embodiment, the driven rollers 520 and 522 are coupledto a drive shaft 524 and the drive shaft 524 is operatively coupled to amotor located inside the housing 194. In some cases, the drive shaft 514is keyed (e.g., D-shaped) and the driven rollers 520 and 522 arecorrespondingly keyed to deter rotation of the driven rollers 520 and522 with respect to the drive shaft 514. Other components of theproximal and distal drive roller assemblies 516 and 518 that are locatedaround the drive shaft 524 may not be keyed so that those othercomponents of the proximal and distal drive roller assemblies 516 and518 are not driven by the drive shaft 524.

The foam-in-bag system 100 also includes a proximal nip roller assembly526 and a distal nip roller assembly 528. The proximal nip rollerassembly 526 includes a nip roller 530 and the distal nip rollerassembly 528 includes a nip roller 532. When the front lower cover 512is closed, the nip roller 530 is arranged to back the proximal drivenroller 520 and the nip roller 532 is arranged to back the distal drivenroller 522. The film can be fed between the driven rollers 520 and 522and the nip rollers 530 and 532. In some embodiments, the film isarranged such that the proximal side of the film (e.g., the side of thefilm with the two longitudinal edges) passes between the proximal drivenroller 520 and the nip roller 530 and the distal side of the film (e.g.,the side of the film with the longitudinal fold) passes between thedistal roller 522 and the nip roller 532. When the drive shaft 524 isdriven by the motor, the drive shaft 524 drives the driven rollers 520and 522 to rotate in the same direction. The interaction of the drivenrollers 520 and 522 and the nip rollers 530 and 532 causes the niprollers 530 and 532 to rotate in the opposite direction. Thecounter-rotating driven rollers 520 and 522 and nip rollers 530 and 532advance the film along a feed path.

In the depicted embodiment, the proximal nip roller assembly 526includes a clamping mechanism 534 and the distal nip roller assembly 528includes a clamping mechanism 536. The clamping mechanisms 534 and 536are configured to be clamped after the front lower cover 512 is closedto hold the nip rollers 530 and 532 in position against the drivenrollers 520 and 522 and to prevent the front lower cover 512 fromopening inadvertently. In some embodiments, the clamping mechanism 534is configured to be selectively clamped to the housing 194, to acomponent fixedly coupled to the housing 194, or to the proximal driveroller assembly 516. In some embodiments, the clamping mechanism 536 isconfigured to be selectively clamped to the distal drive roller assembly518. In the depicted embodiment, the clamping mechanisms 534 and 536 arelevers that are coupled to brackets and the brackets are arranged toengage a portion of one of the housing 194, a component fixedly coupledto the housing 194, the proximal drive roller assembly 516, or thedistal drive roller assembly 518. In other embodiments, the clampingmechanisms 534 and 536 can be any other mechanism that is capable ofbeing selectively clamped.

In the depicted embodiment, a longitudinal sealer 538 is located withthe proximal driven roller 520. The longitudinal sealer 538 isconfigured to create a longitudinal seal in the film as the film passesbetween the proximal driven roller 520 and the nip roller 530. In someembodiments, the longitudinal sealer 538 includes a heating elementconfigured to be heating to a temperature that causes a heat seal to beformed between the two plies of film. In this way, the longitudinalsealer 538 is configured to form a longitudinal seal near the twolongitudinal edges of the film to form the side of the bags. Specificnew embodiments of longitudinal heat sealers are discussed below. Otherembodiments of heat sealers are already known in the art and are readilyavailable to those skilled in the art.

The foam-in-bag system 100 is also configured to form transverse sealsin the film to form the tops and bottoms of bags and to make transversecuts in the film to separate bags. In the depicted embodiment, thefoam-in-bag system 100 includes a seal and cut jaw 540 located below thedrive shaft 524. The foam-in-bag system 100 also includes a backing jaw542 on the front lower cover 512. When the front lower cover 512 isclosed, the backing jaw 542 is aligned with the seal and cut jaw 540 sothat the transverse width of the film passes between the seal and cutjaw 540 and the backing jaw 542. In some embodiments, the seal and cutjaw 540 is configured to move with respect to the backing jaw 542 sothat the seal and cut jaw 540 can be moved toward the backing jaw 542 toform transverse seals and/or transverse cuts in the film and the sealand cut jaw 540 can be moved away from the backing jaw 542 to allow abag to pass between the seal and cut jaw 540 and the backing jaw 542. Insome cases, the seal and cut jaw 540 can be pulled back from the backingjaw 542 a sufficient distance to permit a bag having chemical precursorand/or resulting foam inside to pass between the seal and cut jaw 540and the backing jaw 542. While it has been described here as the sealand cut jaw 540 only moving, it will be appreciated that any respectivemovement of the seal and cut jaw 540 and the backing jaw 542 is possibleto accomplish the same outcome, such as movement of both the seal andcut jaw 540 and the backing jaw 542 toward and away from each other ormovement of the backing jaw only toward and away from the seal and cutjaw 540. In some embodiments, the seal and cut jaw 540 includes threeheating elements that are substantially parallel to each other: twosealing heating elements arranged transversely and a cutting elementarranged transversely between the two sealing heating elements. When thefilm is clamped between the seal and cut jaw 540 and the backing jaw542, the two sealing heating elements form a top transverse seal in onebag and a bottom transverse seal in a subsequent bag and the cuttingheating element cuts the film transversely between the top and bottomtransverse seals.

As can be seen when comparing the instance of the foam-in-bag system 100shown in FIGS. 6A and 6B to the instance of the foam-in-bag system 100shown in FIGS. 6C and 6D, the foam-in-bag system 100 is able toaccommodate rolls 400 of film having different widths. One advantage tothe embodiment of the foam-in-bag system 100 described herein is thereduced amount of time and effort required to adjust the foam-in-bagsystem 100 to accommodate a different width of the roll 400 as comparedto existing foam-in-bag machines. Existing foam-in-bag systems arecenter-justified with the chemical dispenser arranged in a central,fixed position. The remaining components, such as edge seals, rollers,venting mechanisms, and the like, must be reconfigured or replacedaround the central position of the chemical dispenser. Suchreconfigurations can be time consuming and require significant effort.In addition, the reconfigurations may require additional parts, such asreplacement assemblies that are used for different widths of film. Thecost of the additional parts and the energy and space to inventory suchadditional parts increases the difficulty in this type of areconfiguration. Moreover, existing foam-in-bag systems includecomputing devices that control their operations; however, the computingdevices in existing foam-in-bag systems do not automatically account formechanical reconfigurations. For example, a foam-in-bag system may beset up to feed film with a 19-inch transverse width and to controldispensing so that bags are filled with foam to 80% of capacity. Thefoam-in-bag system may then be adjusted by a user to feed film with a12-inch transverse width. If the control system is not likewiseadjusted, the foam-in-bag system will dispense the same about ofchemical precursor into the 12-inch wide bag as it dispensed to fill19-inch wide bags to 80% of capacity, resulting in an overfill of the12-inch wide bags.

In the embodiment of the foam-in-bag system 100, one advantage of thefoam-in-bag system 100 is that reconfiguration of the foam-in-bag system100 for different widths of the roll 400 is less time-consuming andrequires less effort than other existing foam-in-bag systems. Inparticular, the foam-in-bag system is not center-justified, butside-justified to the proximal side of the film regardless of the widthof the film. More specially, as can be seen when comparing FIGS. 6A and6B to FIGS. 6C and 6D, the proximal wing 406 of the spindle system 402,the proximal drive roller assembly 516, and the proximal nip rollerassembly 526 are configured to be in the same position regardless of thewidth of the roll 400 and the film. In contrast, as can be seen whencomparing FIGS. 6A and 6B to FIGS. 6C and 6D, the distal wing 408, thedistal drive roller assembly 518, and the distal nip roller assembly 528are configured to be moved to different positions based on the width ofthe roll 400 and the film. It will be apparent to those skilled in theart that the foam-in-bag system could also be side-justified to thedistal side of the film if desired.

In some embodiments, the distal wing 408, the distal drive rollerassembly 518, and the distal nip roller assembly 528 are positionable bya user without the use of tools. As discussed above with respect to FIG.5A, the distal wing 408 is transversely positionable along the rod 404by releasing the distal ring clamp 426, repositioning the distal wing408, and then clamping the distal ring clamp 426 again. The distal driveroller assembly 518 is transversely positionable along the drive shaft524. In the depicted embodiment, the distal drive roller assembly 528 isselectively held in place by a cam handle 546 located in a slot 548 ofthe housing 194. The distal drive roller assembly 518 is transverselypositionable along the drive shaft 524 by releasing the cam handle 546,repositioning the distal drive roller assembly 518, and then clampingthe cam handle 546 again. The distal nip roller assembly 528 ispositionable transversely along the front lower cover 512. In thedepicted embodiment, when the front lower cover 512 is closed, theclamping mechanism 536 is configured to be clamped to a portion of thedistal drive roller assembly 518. In this way, the clamping of theclamping mechanism 536 to the distal drive roller assembly 528 holds thedistal nip roller assembly 528 in a transverse corresponding to thetransverse position of the distal drive roller assembly 518.

The transverse position of the chemical dispenser 174 can be fixed oradjustable. In some embodiments, the dispenser 174 is fixed in aposition that is within the range of the narrowest possible width offilm. In some embodiments, the dispenser 174 can be moved manuallyduring the reconfiguration of the distal wing 408, the distal driveroller assembly 518, and the distal nip roller assembly 528. In someembodiments, the foam-in-bag system 100 includes a sensor to detect thetransverse position of one or more of the distal wing 408, the distaldrive roller assembly 518, and the distal nip roller assembly 528, andto automatically move the dispenser to a particular transverse location(e.g., approximately at the midpoint between the proximal and distaldrive roller assemblies 516 and 518).

In the depicted embodiment, the foam-in-bag system 100 is configuredautomatically adjust one or more dispensing functions based on theposition of an adjustable component of the foam-in-bag system 100. Inone example, the foam-in-bag system 100 includes a sensor configured todetect a location of the distal drive roller assembly 518 and to controlan amount of the chemical precursors dispensed from the dispenser 174into each bag. For example, if the sensor detects that the distal driveroller assembly 518 has been moved from a location where it accommodateda 16-inch-wide film to a location where it accommodates a 12-inch-widefilm, the foam-in-bag system may automatically reduce the amount ofchemical precursor dispensed into each bag by 25%. It will be apparentto those skilled in the art that the percent change in the amount ofchemical precursor dispensed may or may not be the same as the percentchange in the width of the film indicated by the movement of the distaldrive roller assembly 518. It will also be apparent that the sensor maydetect movement of any component, such as the distal wing 408, thedistal drive roller assembly 518, or the distal nip roller assembly 528.

Depicted in FIGS. 7A, 7B, and 7C are side, perspective, andcross-sectional perspective views of an embodiment of the longitudinalsealer 600 that can be used to form longitudinal seals in film. Forexample, the longitudinal sealer 600 can be used as the longitudinalsealer 538 in the embodiment shown in FIGS. 6A to 6D. The longitudinalsealer 600 includes a housing 602 and an arm 604. In some embodiments,the exteriors of the housing 602 and the arm 604 are made from a plasticmaterial or another resilient material. The arm 604 extends from thehousing 602. In some embodiments, the arm 604 is capable of moving withrespect to the housing 602.

In some embodiments, the longitudinal sealer 600 is placed at leastpartly around a shaft (e.g., drive shaft 524). In the depictedembodiment, the housing 602 is shaped with surfaces 606 and the arm 604is shape with an interior surface 608. The surfaces 606 and the interiorsurface 608 are configured to accommodate at least a portion of theshaft between a portion of the housing 602 and a portion of the arm 604.The sizes and orientations of the surfaces 606 and the interior surface608 may be selected based on a size of the shaft.

In some embodiments, the longitudinal sealer 600 is configured to beinstalled in and removed from a foam-in-bag system by a user manuallywithout the use of tools. In the depicted embodiment, the housing 602includes slots 610—one of which is visible in FIGS. 7A and 7B and theother of which is on the opposite side of the housing 602 and notvisible in FIGS. 7A and 7B—that can be used to slide the longitudinalsealer 600 into place in the foam-in-bag system. For example, thefoam-in-bag system may have a C-shaped bracket configured such that theportion of the housing 602 between the slots 610 is capable of beingslid in the gap of the C-shaped bracket with the ends of the C-shapedbracket located in the slots 610. One of the slots 610 includes a bore612 that is capable of engaging a pin, such as a spring-loaded pin onthe C-shaped bracket. That one of the slots 610 also includes a pinengagement surface 614 near the bottom of the housing 602. The pinengagement surface 614 is configured such that, as the housing 602 isslid into the C-shaped bracket, the pin engagement surface 614 engagesthe pin in its fully extended position and pushes the pin back so thatthe pin accommodates the slot 610 and then is automatically engaged intothe bore 612. In this way, a user can install the longitudinal sealer600 manually without tools by sliding the longitudinal sealer 600 intothe C-shaped bracket until the pin locks into the bore 612. To removethe longitudinal sealer 600 from the C-shaped bracket, a user pulls thepin back out of the bore 612 and then lifts the longitudinal sealer 600from the C-shaped bracket so the slot 610 is withdrawn from the C-shapedbracket. To aid a user in installing and/or removing the longitudinalsealer 600, the housing 602 includes a tab 616 that is convenient for auser to grasp when installing and/or removing the longitudinal sealer600.

The arm 604 of the longitudinal sealer 600 includes a heating element618. The heating element 618 is configured to be heated to a temperatureat which a heat seal is formed in film when the film comes into contactwith the heating element 618. In some embodiments, the heating element618 includes a resistive heater that generates heat in response toelectrical current being passed through the resistive heater and thetemperature of the resistive heater can be controlled by controlling theamount of electrical current that is passed through the resistiveheater. In some embodiments, the heating element 618 is made from aceramic material, such as one or more of a crystalline oxide, nitride orcarbide material, an aluminum oxide, a silicon carbide, or a tungstencarbide. The heating element 618 has a leading edge 620 that is exposedthrough an exterior surface 622 of the arm 604. When the heating element618 is heated, the exposed leading edge 620 is capable of forming a heatseal in film that passes along the exterior surface 622 of the arm 604.In some embodiments, the area of the leading edge 620 that is exposedthrough the exterior surface 622 of the arm 604 is selected based on acharacteristic of the heat seal to be formed, such as a desired size ofthe heat seal to be formed, a thickness of film in which the heat sealis to be formed, a material of the film in which the heat seal is to beformed, or any other characteristic.

As noted above, the heating element 618 can be heated by passingelectrical current through the heating element 618 and the temperatureof the heating element 618 can be controlled by controlling the amountof electrical current passing through the heating element 618. Theheating element 618 includes a temperature sensor 624. In someembodiments, the temperature sensor 624 includes one or more resistancetemperature detectors (RTDs), thermocouples, thermistors, or any othertype of temperature sensor. In one embodiment, the temperature sensor624 includes a first RTD embedded within the heating element 618 and asecond RTD located on an exterior surface of the heating element 618.The temperature sensor 624 is configured to generate one or more signalsindicative of one or more temperatures of the heating element 618. Itshould be noted that the temperature sensor 624 may generate multiplesignals indicated of different temperatures in the heating element 618,such as a temperature inside the heating element 618 generated by an RTDembedded in the heating element 618 and a temperature on the surface ofthe heating element 618 generated by an RTD located on an exteriorsurface of the heating element 618. In such cases, a controller can takeinto account the signals when determining how to control the amount ofelectrical current to supply to the heating element 618.

The heating element 618 includes electrical leads 626. The electricalleads 626 are electrically coupled to the heating element 618 and to thetemperature sensor 624. The electrical leads 626 are configured to becoupled to wires that electrically coupled the heating element 618 andto the temperature sensor 624 to a controller (e.g., a computing device)in the foam-in-bag machine. In the depicted embodiment, the arm 604includes a conduit 628 through which the wires can pass. The housing 602includes a stress relief 630 through which the wires can be wound todeter the possibility of the wires becoming disconnected from theelectrical leads 626. In some embodiments, the wires can pass out of thehousing 602 to an electrical connector so that, when the longitudinalsealer 600 is installed in a foam-in-bag system, the electricalconnector can be coupled to a mating connector of a controller in thefoam-in-bag system. In other embodiments, the housing 602 can include acommunication mechanism that is capable of communicating with thecontroller in the foam-in-bag system when the longitudinal sealer 600 isinstalled on the foam-in-bag system. The communication mechanism in thehousing 602 can include one or more of electrical contacts on theexterior of the housing 602 that mate with electrical contacts on thefoam-in-back system (e.g., on a C-shaped bracket) when the longitudinalsealer 600 is installed in the foam-in-bag system or a wirelesscommunication mechanism (e.g., a WiFi transceiver, a Bluetoothtransceiver, a NFC transceiver, an induction communication mechanism,etc.) configured to communicate with a corresponding wirelesscommunication mechanism in the foam-in-bag system.

In the depicted embodiment of the longitudinal sealer 600, the arm 604is capable of moving with respect to the housing 602. This movement ofthe arm 604 allows the leading edge 620 of the heating element 618 to bebrought into contact with film and withdrawn back from contact with thefilm. In the depicted embodiment, the housing includes a post 632 thatpasses through the arm 604. The arm 604 is configured to rotate aboutthe post 632. In some embodiments, the housing 602 permits the arm 604to rotate within a range of less than or equal to about 2 degrees ofrotation. With such a small range of rotation, the movements of the arm604 may appear to be small linear movements with the portion of the arm604 extending from the housing 602 appearing to move linearly toward andaway from the film.

In the depicted embodiment, the longitudinal sealer 600 includes abiasing element 634 configured to bias the arm 604 to one end of therange of rotation of the arm 604. In the embodiment shown in FIG. 7C,the biasing element 634 biases the arm 604 to rotate in the clockwisedirection so that the leading edge 620 of the heating element 618 iswithdrawn toward the housing 602 as far as possible. In someembodiments, the biasing element 634 includes a compression spring thatis under compression between the arm 604 and the housing 602.

In the depicted embodiment, the longitudinal sealer 600 also includes aplunger 636 that is capable of being moved to initiate movement of thearm 604. The plunger 636 passes through the housing 602 so that one endof the plunger 636 is outside of the housing 602. The plunger 636includes a spring-loaded end 638 on the inside of the housing. The endof the plunger 636 outside of the housing 602 can be pushed toward thehousing 602, resulting in the spring-loaded end 638 pushing the arm 604to rotate in the counterclockwise direction and extend the leading edge620 of the heating element 618 away from the housing 602. The arm 604will rotate in the counterclockwise direction when the torque exerted onthe arm 604 exceeds the torque applied to the arm 604 by the biasingelement 634. The spring-loaded end 638 deters the plunger 636 fromexerting too great a force on the arm 604, even when the plunger 636such a force is applied to the end of the plunger 636 outside of thehousing 602.

Depicted in FIGS. 7D and 7E are side and cross-sectional side views,respectively, of the longitudinal sealer 600 with the arm 604 retractedtoward the housing 602 and the longitudinal sealer 600 installed in thefoam-in-bag system 100. Depicted in FIGS. 7F and 7G are side andcross-sectional side views, respectively, of the longitudinal sealer 600with the arm 604 extended out from the housing 602 and the longitudinalsealer 600 installed in the foam-in-bag system 100. In both instances,the longitudinal sealer 600 is installed in to a C-shaped bracket 640that is fixedly coupled to the housing 194 of the foam-in-bag system100. The ends of the C-shaped bracket 640 are arranged to engage theslots 610 of the housing 602 with the portion of the housing 602 betweenthe slots located in the gap between the ends of the C-shaped bracket640. The C-shaped bracket 640 includes a spring-loaded pin 642, one endof which is configured to engage the bore 612 in one of the slots 610.The other end of the spring-loaded pin 642 includes a handle 644configured to permit a user to grasp and pull the end of thespring-loaded pin 642 out of the bore 612.

FIGS. 7D to 7G depict a film path 646 that passes between the proximaldriven roller 520 and the nip roller 530. The longitudinal sealer 600 isheld in place by the C-shaped bracket 640 so that a portion of the arm604 is located in the middle of or adjacent to the proximal drivenroller 520. The arm 604 is capable of being moved between a positionwhere the leading edge 620 of the heating element 618 is not in contactwith film in the film path 646 (as shown in FIGS. 7D and 7E) and aposition where the where the leading edge 620 of the heating element 618is in contact with film in the film path 646 (as shown in FIGS. 7F and7G). In this way, the heating element 618 can be controlled toselectively contact the film in the film path 646.

In the depicted embodiment, the arm 604 is moved by an actuator 648 ofthe foam-in-bag system 100. The actuator 648 is fixedly coupled to thehousing 194. In some embodiments, the actuator 648 may be any form oflinear actuator, such as an electric motor (e.g., a solenoid) and a leadscrew, a rack and pinion device, a driven cam, another electromechanicalactuator, or any other type of actuator. The actuator 648 includes anactuator arm 650 that is driven linearly by the actuator 648 and isconfigured to engage the plunger 636 of the longitudinal sealer 600 andto exert a force on the plunger 636. In the instance shown in FIGS. 7Dand 7E, either the actuator arm 650 does not contact the plunger 636 orthe force exerted by the actuator arm 650 on the plunger does not resultin enough torque on the arm 604 to overcome the torque exerted by thebiasing element 634. In this instance, the biasing element 634 causesthe arm 604 to rotate as far as permitted by the housing 602 in adirection (i.e., clockwise in the views shown in FIGS. 7D to 7G) so thatthe leading edge 620 of the heating element 618 is not in contact withfilm in the film path 646. In the instance shown in FIGS. 7F and 7G, theforce exerted by the actuator arm 650 on the plunger 636 provides enoughtorque on the arm 604 to overcome the torque exerted by the biasingelement 634. In this instance, the plunger 636 causes the arm 604 torotate as far as permitted by the housing 602 in the opposite direction(i.e., counterclockwise in the views shown in FIGS. 7D to 7G) so thatthe leading edge 620 of the heating element 618 is in contact with filmin the film path 646. In some embodiments, the actuator 648 iscontrolled by a controller (not shown), such as a controller in thefoam-in-bag system 100. For example, the controller that controls theamount of electrical current provided to the heating element 618 mayalso control the actuator 648 so that the position of the arm 604 iscontrolled.

The embodiment of the longitudinal sealer 600 shown in FIGS. 7A to 7Gprovides a number of benefits over existing longitudinal sealers inexisting foam-in-bag systems. One example of a benefit is that thelongitudinal sealer 600 is capable of being controlled in a number ofways. The longitudinal sealer 600 can be controlled in one or more ofthe following ways: the heating element 618 is maintained within a rangeof a target temperature (e.g., within any one of 1° C., 2° C., or 5° C.of a target temperature), the position of the arm 604 with respect tothe film path 646 can be controlled to control contact of the heatingelement 618 with the film, or the force exerted by the actuator 648 onthe plunger 636 can be controlled to control a level of force of theheating element 618 on the film. This controllability allows thelongitudinal sealer 600 to be used to form seals in the film with betterquality and with better consistency than other longitudinal sealers thatcannot be controlled in this way. The controllability also allowsreduces the potential for the longitudinal sealer 600 to create a defectin film. For example, existing longitudinal sealers cannot be withdrawnfrom the film when the foam-in-bag stops forming bags and the heatingelement in the existing longitudinal sealers does not cool immediately,sometimes resulting in the heating element heating the stopped filmuntil a hole forms in the film. In contrast, the arm 604 of thelongitudinal sealer 600 can be moved into or out of contact with thefilm rapidly (e.g., within 10 milliseconds from the time at which thecontroller signals the actuator 648). The reduces the possibility of theheating element 618 forming a hole or other defect in the film when thefilm stops.

Another example of a benefit of the longitudinal sealer 600 is thedurability of the longitudinal sealer 600. Existing longitudinal sealerstend to wear out from abrasion due to contact with the film. Films usedin foam-in-bag situations are typically abrasive due to additives usedas colorants and/or to ensure printing on the film does not easily wearoff. However, the abrasiveness of the film can create wear on heatingelements of longitudinal sealers when the heating elements areconstantly in contact with the film and/or housings of longitudinalsealers when the housings of longitudinal sealers are not made from arobust material. In some embodiments, the heating element 618 is madefrom a durable ceramic material that will not wear due to prolongedcontact with the film. In addition, the ability of the arm 604 towithdraw from the film when the heating element 618 is not sealing filmreduces the amount of time that the heating element 618 is in contactwith the film. In some embodiments, wear on the heating element 618 isreduced by the heating element 618 not being in contact with the filmwhen the arm 604 is withdrawn from the film. Heating elements inexisting foam-in-bag systems tend to wear out from overheating. Theability to control the temperature of the heating element 618 in thelongitudinal sealer 600 reduces the possibility of overheating theheating element 618.

Depicted in FIG. 8A is an embodiment of a jaw assembly 700 that can beused to form transverse seals and cuts in film. For example, the jawassembly 700 can be used as the seal and cut jaw 540 in the embodimentshown in FIGS. 6A to 6D. The jaw assembly 700 includes a bar 702. Insome embodiments, the bar 702 is made from a rigid material, such as ametal (e.g., aluminum), a metal alloy, a ceramic material, a thermosetplastic material, or any other rigid material. In some embodiments, thewidth of the bar 702 (i.e., the dimension of the bar 702 in thetransverse direction D_(T)) is selected such that the bar 702 is widerthan an expected maximum transverse width of film that is to be used ina foam-in-bag system.

The bar 702 includes a lateral side 704. The jaw assembly 700 includes afirst heating element 706, a second heating element 708, and a thirdheating element 710. In the depicted embodiment, the first, second, andthird heating elements 706, 708, and 710 are arranged substantiallyparallel to each other in the transverse direction D_(T) and they arespaced apart in the longitudinal direction D_(Lo). The first heatingelement 706 is held across the lateral side 704 of the bar 702 by posts712, the second heating element 708 is held across the lateral side 704of the bar 702 by posts 714, and the third heating element 710 is heldacross the lateral side 704 of the bar 702 by posts 716. In someembodiments, the posts 712, 714, and 716 are quick-release elements thatare configured to be disengaged from the bar 702 by a user by handwithout the use of tools. In the case that the posts 712, 714, and 716are quick-release elements, a user will be able to remove the posts 712,714, and 716 to replace the heating elements 706, 708, and 710 fasterthan a user is able to remove and replace heating elements in existingfoam-in-bag systems. In some embodiments, the posts 712, 714, and 716fit into holes in the bar 702. In some embodiments, an end of each ofthe posts 712, 714, and 716 includes an electrical contact that isconfigured to engages with an electrical contact inside the hole in thebar 702 such that an electrical contact is made between the electricalcontacts in the holes in the bar 702 and the first, second, and thirdheating elements 706, 708, and 710 when the posts 712, 714, and 716 areinserted into the holes in the bar 702.

The jaw assembly 700 includes a low-adhesion mechanism 718 that coversthe lateral side 704 of the bar 702. The low-adhesion mechanism 718 isconfigured to cover at least one of the first, second, and third heatingelements 706, 708, and 710. In the depicted embodiment, the first andthird heating elements 706 and 710 are covered by the low-adhesionmechanism 718, while the second heating element 708 is not covered bythe low-adhesion mechanism 718. A partial view of this arrangement ofthe low-adhesion mechanism 718 with respect to the first, second, andthird heating elements 706, 708, and 710 is depicted in FIG. 8B. In thisarrangement, the first and third heating elements 706 and 710 may beused to form a transverse seal in two plies of film and the secondheating element 708 may be used to form a transverse cut in the twoplies of film. By closing the jaw assembly 700 against a backing surface(e.g., backing jaw 542) with two plies of film in between, the thirdheating element 710 forms a top transverse seal between the two filmplies in one film bag, the first heating element 706 forms a bottomtransverse seal between the two film plies in a subsequent film bag, andthe second heating element 708 makes a transverse cut in the filmbetween the two film bags.

Low-adhesion surfaces have been used in conjunction with transverseheating elements in existing foam-in-bag systems. These low-adhesionsurfaces lower the probability of film becoming jammed or stuck in thearea with the transverse heating elements as cuts and seals are formedin the film. In existing foam-in-bag systems, the low-adhesion surfaceswere adhered to jaw bars to avoid the issue of a molten material from acut or a seal adhering to the jaw bars. In some examples, tape having alow-adhesion surface (e.g., polytetrafluoroethylene-coated tape) hasbeen adhered to cover a jaw bar surface and heating elements that areused to form seals. This tape with the low-adhesion surface provided thebenefits of the low-adhesion surface during normal operation. However,the tape proved cumbersome when removing and replacing the coveredheating elements. More specifically, when the tape was removed, it wouldfrequently break up into many small pieces that needed to be peeled orscratched off and leave behind adhesive residue on the jaw bar and/orthe heating wires. Once the heating wires were replaced, new tape with alow-adhesion surface needed to be applied to the surface and the newheating wires. However, applying new tape was difficult to properlyalign and adhere, and often had air bubbles or creases that decreasedthe effectiveness of the low-adhesion surface.

In the embodiment shown in FIGS. 8A and 8B, the low-adhesion mechanism718 is a quick-change low-adhesion mechanism that overcomes thedifficulties with previous attempts at low-adhesion surfaces, such astapes with low-adhesion surfaces. The low-adhesion mechanism 718 isdepicted alone in FIG. 8C. As can be seen in FIG. C, the low-adhesionmechanism 718 includes a low-adhesion material 720 that spans between afirst connector 722 and a second connector 724. In the depictedembodiment, the low-adhesion material 720 is a flexible material, suchas a fabric, a film, or other flexible sheet. The first and secondconnectors 722 and 724 are rigid or semi-rigid to enable the first andsecond connectors 722 and 724 to couple the low-adhesion material 720 tothe bar 702. In the depicted embodiment, a distal end 726 of the firstconnector 722 has a U-shaped cross-section and the distal end 728 of thesecond connector 724 has a snap-in connector. In some embodiments, thefirst and second connectors 722 and 724 are make from plastic that iseither injection-molded and/or extruded.

To place the low-adhesion mechanism 718 on the bar 702, the distal end726 of the first connector 722 is secured to a protrusion and/or agroove on the top of the bar 702, the low-adhesion material 720 iswrapped around the lateral side 704 of the bar, and then the distal end728 of the second connector 724 is snapped into a mating snap-inconnector on the bottom of the bar 702. To remove the low-adhesionmechanism 718 from the bar 702, the distal end 728 of the secondconnector 724 is removed from the mating snap-in connector on the bottomof the bar 702, unwrapped from the lateral side 704 of the bar 702, andthe distal end 726 of the first connector 722 is removed from theprotrusion and/or the groove on the top of the bar 702. This method ofplacing the low-adhesion mechanism 718 on and removing the low-adhesionmechanism 718 from the bar 702 eliminate the problems that arose fromthe use of low-adhesion tape and other adhered low-adhesion surfaces,thereby greater reducing the amount of time and complexity of placingand removing the low-adhesion mechanism 718.

As described above, respective movement of a seal and cut jaw (e.g., theseal and cut jaw 540) and a backing jaw (e.g., the backing jaw 542) canbring the seal and cut jaw and the backing jaw together. If film is inbetween the seal and cut jaw and the backing jaw, the heating elementson the seal and cut jaw can be used to seal and/or cut the film.Similarly, a film can be fed between the jaw assembly 700 and a backingjaw. Respective movement of the jaw assembly 700 and the backing jaw canbring the jaw assembly 700 and the backing jaw together so that thefirst, second, and third heating elements 706, 708, and 710 can be usedto seal and/or cut the film. An embodiment of a movement system 730configured to move the jaw assembly 700 toward and away from a backingjaw 732 in a lateral direction D_(La) is depicted in FIGS. 8D and 8E.More specifically, FIG. 8D depicts a top view of the jaw assembly 700withdrawn from the backing jaw 732 in the lateral direction D_(La) andFIG. 8E depicts a top view of the jaw assembly 700 after the jawassembly has been moved in the lateral direction D_(La) up to thebacking jaw 732.

The movement system 730 includes a driving mechanism 734. In thedepicted embodiment, the driving mechanism 734 is a motor configured toselectively generate a rotational force in two rotational directions(e.g., clockwise and counterclockwise). In other embodiments, thedriving mechanism 734 may be an engine, a pump, or any other mechanismconfigured to generate a force. In the depicted embodiment, the drivingmechanism 734 is coupled to a threaded rod 736. The threaded rod 736 iscoupled to the driving mechanism 734 such that rotational force providedby the driving mechanism 734 will engage the thread of the threaded rod736, causing linear translation of the threaded rod 736 in thetransverse direction D_(T). In the depicted embodiment, the threaded rod736 will move in one linear direction (e.g., in the positive transversedirection D_(T)) when the driving mechanism 734 provides rotationalforce in one rotational direction (e.g., counterclockwise) and thethreaded rod 736 will move in the opposite linear direction (e.g., inthe negative transverse direction D_(T)) when the driving mechanism 734provides force in the opposite rotational direction (e.g., clockwise).

The threaded rod 736 is coupled to a toggle 738. In the depictedembodiment, one side of the toggle 738 includes a roller 740 configuredto move within a slot 742. The other side of the toggle 738 is rotatablyconnected to the bar 702 of the jaw assembly 700. Any linear movement ofthe threaded rod 736 in the transverse direction D_(T) results incorresponding movement of the roller 740 in the transverse directionD_(T). The interaction of the roller 740 in the slot 742 causes thetoggle 738 to exert a force on the bar 702 to move the jaw assembly 700toward or away from the slot 742 in the lateral direction D_(La). Inother embodiments, the roller 740 may be replaced by any device, such asa slider, capable of moving laterally while remaining rotatably coupledto the toggle 738.

The lateral side 704 of the jaw assembly 700 is aligned with a lateralside 744 of the backing jaw 732 such that the jaw assembly 700 can bemoved between a position where the lateral side 704 of the jaw assembly700 is withdrawn from the lateral side 744 of the backing jaw 732 (asshown in FIG. 8D) and a position where the lateral side 704 of the jawassembly 700 is abuts the lateral side 744 of the backing jaw 732 (asshown in FIG. 8E). When film is placed between the jaw assembly 700 andthe backing jaw 732 in the orientation shown in FIG. 8D, the film ispermitted to be fed in the longitudinal direction D_(Lo) (e.g., in adirection into the page as seen by a viewer of FIG. 8D) past the jawassembly 700 and the backing jaw 732. When film is placed between thejaw assembly 700 and the backing jaw 732 in the orientation shown inFIG. 8E, the film is held between the jaw assembly 700 and the backingjaw 732 so that the film can be sealed and/or cut by the heatingelements 706, 708, and 710 on the lateral side 704 of the jaw assembly.In the depicted embodiment, the jaw assembly 700 includes lateral guides746 on either transverse side of the bar 702 of the jaw assembly 700 toproperly guide movement of the bar 702 when the movement system 730moves the jaw assembly laterally (e.g., to maintain alignment of thelateral side 704 of the jaw assembly 700 with the lateral side 744 ofthe backing jaw 732).

One advantage of the roller system shown in FIGS. 8D and 8E is a safetyfeature inherent in the arrangement of the movement mechanism withrespect to the jaw assembly 700. When the threaded rod 736 exerts aconstant force on the toggle 738 in the transverse direction D_(T), thetoggle 738 will exert a varying force on the jaw assembly 700 in thelateral direction D_(La). When the jaw assembly 700 is closer to theposition shown in FIG. 8D, the toggle 738 exerts a relatively low forceon the jaw assembly 700 in the lateral direction D_(La). When the jawassembly 700 is closer to the position shown in FIG. 8E, the toggle 738exerts a relatively high force on the jaw assembly 700 in the lateraldirection D_(La). If a foreign object is inserted between the jawassembly 700 and the backing jaw 732 when the jaw assembly 700 is in theposition shown in FIG. 8D, the closing motion of the jaw assembly 700will exert a relatively low force on the foreign object because thetoggle 738 does not exert a high force on the jaw assembly 700 until thejaw assembly 700 is close to the backing jaw 732. In some embodiments,any contact of the jaw assembly 700 with the foreign object will notresult in damage to the foam-in-bag system. In addition, in someembodiments, when the foreign object is a body part of a user (e.g., auser's hand or fingers), any contact of the jaw assembly 700 with thebody part will not result in significant injury to the user.

In the embodiment shown in FIGS. 8A to 8E, the second heating element708 is on the same side of the jaws (i.e., on the lateral side 704 ofthe jaw assembly 700) as the first and third heating elements 706 and710. In existing foam-in-bag systems, the transverse heating elementthat cuts the film (sometimes called a “cut wire”) is located on thenon-moving side of the jaws and the heating elements that seal the film(sometimes called “seal wires”) are located on the moving side of thejaws. This design in existing foam-in-bag systems can be problematicwith the cut wire on the non-moving portion of the jaw because the filmcan become stuck on the cut wire or the film can be jammed on the cutwire. It could also create an unintended seal midway through a bag,which could result in a foam-up situation (e.g., where the foam expandsoutside of the bag) or other error resulting in shut down of themachine. By placing the second heating element 708 on the moving jawassembly 700, the foam-in-bag system 100 moves the cut wire out of theway of the film being fed to avoid jamming the film on the secondheating element 708. In addition, if a bag becomes stuck on the secondheating element 708 during the cutting action, the withdrawing of thejaw assembly 700 back from the natural path of the film will encouragethe bag to release from the second heating element 708 without jammingthe foam-in-bag system 100.

Depicted in FIGS. 9A to 9D are instances of a foam-in-bag system 810that forms bags from film 812, fills the bags with foaming chemicalprecursors, and closes the bags with the foaming chemical precursorsinside. In the depicted embodiment, the film 812 includes a transversefold 814 and two longitudinal edges 816. The portion of the film 812 onone side of the transverse fold 814 passes in front of a dispenser 818and the portion of the film 812 on the other side of the transverse fold814 passes in back of the dispenser 818. Thus, one of the longitudinaledges 816 is in front of the dispenser 818 and the other of thelongitudinal edges 816 is in back of the dispenser 818.

The foam-in-bag system 810 includes a proximal set of rollers 820 and adistal set of rollers 822 that are configured to feed the film 812. Inthe depicted embodiment, the proximal and distal sets of rollers 820 and822 are configured to feed the film 812 in a downward direction. Theproximal set of rollers 820 includes a longitudinal sealer (not shown),such as the longitudinal sealer 600, that forms a longitudinal seal 824in the film 812 near the two longitudinal edges 816 to close the leftside of the film 812. In the depicted embodiment, the distal set ofrollers 822 does not have a longitudinal sealer because the right sideof the film 812 is already closed by the transverse fold 814. In theinstance shown in FIG. 9A, the closed left and rights sides of the film812 form left and right sides of a bag 826.

The foam-in-bag system 810 also includes a front jaw assembly 828 and arear jaw assembly 830. The film 812 is arranged to pass between thefront and rear jaw assemblies 828 and 830. At least one of the front andrear jaw assemblies 828 and 830 is capable of movement toward and awayfrom the other of the front and rear jaw assemblies 828 and 830. Whenthe front and rear jaw assemblies 828 and 830 are brought together withthe film 812 in between, the front and rear jaw assemblies 828 and 830are capable of forming transverse seals and/or transverse cuts in thefilm 812. In the instance shown in FIG. 9A, the front and rear jawassemblies 828 and 830 have already transversely cut the film 812 toform a bottom 832 of the bag 826 and created a transverse seal 834 toclose the bottom 832 of the bag 826.

Each of FIGS. 9A to 9D depicts an instance in a series of operations bythe foam-in-bag system 810. In FIG. 9A, the bottom and the left andright sides of the bag 826 have been closed. The front and rear jawassemblies 828 and 830 are withdrawn from each other to allow the film812 to pass. The dispenser 818 is in the process of dispensing foamingchemical precursors 836 into the bag 826. In FIG. 9A, the foamingchemical precursors 836 may have begun to mix together and form foam,but typically still in a mostly liquid state. In FIG. 9B, the foamingchemical precursors 836 have fallen to the transverse seal 834 near thebottom 832 of the bag 826. From there, the foaming chemical precursors836 continue to form foam and grow in volume.

In FIG. 9C, the front and rear jaw assemblies 828 and 830 are broughttogether with the film 812 in between. The front and rear jaw assemblies828 and 830 transversely cuts the film to separate the bag 826 from therest of the film 812 and to form a top 838 of the bag 826. The front andrear jaw assemblies 828 and 830 also forms a transverse seal 840 in thebag 826 near the top 838 of the bag 826. When the front and rear jawassemblies 828 and 830 are brought together in FIG. 9C, the front andrear jaw assemblies 828 and 830 also begin formation of a subsequent bag842. In addition to separating the bag 826 from the rest of the film812, the transverse cut by the front and rear jaw assemblies 828 and 830also forms a bottom 844 of the subsequent bag 842. The front and rearjaw assemblies 828 and 830 also form a transverse seal 846 near thebottom 844 of the subsequent bag 842 to close the bottom 844 of thesubsequent bag 842. In FIG. 9C, as the front and rear jaw assemblies 828and 830 are forming the transverse cut and the transverse seals 840 and846 in the film 812, the foaming chemical precursors 836 continue toform foam and grow in volume inside the bag 826. At this point, thefoaming chemical precursors 836 may have more of the consistency of foamthan liquid such that the foaming chemical precursors 836 would not flowlike liquid if the orientation of the bag 826 was changed.

In FIG. 9D, the bag 826 is fully separated from the rest of the film 812and is capable of falling downward (as shown in FIG. 9D) or otherwisemoved away from the rest of the film 812. The front and rear jawassemblies 828 and 830 have been moved away from each other to permitthe film 812 to be fed further downward to continue formation of thesubsequent bag 842. The dispenser 818 is also dispensing foamingchemical precursors 848 into the subsequent bag 842 to fill thesubsequent bag 842 with foam. The foaming chemical precursors 836 in thebag 826 also continue to form foam and grow in volume inside the bag826. In some cases, the foaming chemical precursors 836 are capable offorming foam that occupies a space of several hundreds of times greaterthan the volume of the individual foaming chemical precursors beforethey were mixed.

One difficulty with the foam-in-bag system 810 depicted in FIGS. 9A to9D is the location of the growing foam inside the bag 826. The dispenser818 is substantially centered with respect to the left and right sidesof the film 812 so that the foaming chemical precursors 836 aredispensed at and grow from a substantially central location in thetransverse direction (i.e., substantially centered from left to right).However, it is apparent when viewing the instances depicted in FIGS. 9Ato 9D that the foaming chemical precursors 836 do not grow from asubstantially central location in the longitudinal direction (i.e., notsubstantially centered from top to bottom). In particular, thedispensing of the foaming chemical precursors 836 by the dispenser 818,as shown in FIG. 9A, tends to result in the foaming chemical precursors836 falling toward the bottom 832 of the bag 826, as shown in FIG. 9B.When viewing the instance shown in FIGS. 9B to 9D, the growth of thefoaming chemical precursors 836 occurs from near the bottom 832 of thebag 826 and the center of gravity of the resulting foam from the foamingchemical precursors 836 is located nearer the bottom 832 than the top838 of the bag. This unbalance of the foam in the bag 826 may make thebag 826 less effective for use as a protection material and may make itmore difficult for the bag 826 to be fit into a shipping container(e.g., a box) around an object that is located in the shippingcontainer.

One way that operators have overcome the difficulty with the foam-in-bagsystem 810 is to attempt to manually rebalance the foam in the bags. Forexample, operators of the foam-in-bag system 810 are sometimes trainedto grab the leading edge of each bag with both hands as it emerges fromthe foam-in-bag system 810, with one hand on each corner. The operatorsare then trained to raise the leading end of the bag up so the dispensedfoam is prevented from flowing to the bottom of the bag. This helps tocenter the foam along the length of the bag, if need be. However, thismethod of vertical foam centering is manual and subject to the vagariesof operator technique and training. In addition, employees in thepackaging centers often turn over on short notice, so training andexperience are lost easily with frequent turnover.

Depicted in FIGS. 9E to 9I are instances of a foam-in-bag system 850that creates bags with foam inside that are more balanced than the bagscreated by the foam-in-bag system 810. The foam-in-bag system 850includes a number of the same components as are included in thefoam-in-bag system 810, including the film 812, the dispenser 818, theproximal and distal sets of rollers 820 and 822, and the front and rearjaw assemblies 828 and 830.

The foam-in-bag system 850 also includes a front pinch jaw 852 and arear pinch jaw 854. In the depicted embodiment, the front pinch jaw 852has a circular cross-section and the rear pinch jaw 854 has an L-shapedcross section. In other embodiments, the front and rear pinch jaws 852and 854 may have any shape or cross-section. The front and rear pinchjaws 852 and 854 are arranged to permit the film 812 to pass between. Atleast one of the front and rear pinch jaws 852 and 854 is capable ofmovement toward and away from the other of the front and rear pinch jaws852 and 854. When the front and rear pinch jaws 852 and 854 are broughttogether with the film 812 in between, the front and rear pinch jaws 852and 854 pinch the two plies of the film 812 together. When the front andrear pinch jaws 852 and 854 are withdrawn from each other, the two pliesof the film 812 is permitted to separate from each other. The front andrear pinch jaws 852 and 854 are configured to pinch the film 812 withoutcutting or sealing the film 812. As explained below, the front and rearpinch jaws 852 and 854 enable the foam-in-bag system 850 to dispensefoaming chemical precursors so that the resulting foam is more balancedwithin bags.

Each of FIGS. 9E to 9I depicts an instance in a series of operations bythe foam-in-bag system 850. In FIG. 9E, the bottom and the left andright sides of the bag 826 have been closed. The front and rear jawassemblies 828 and 830 are withdrawn from each other to allow the film812 to pass. The front and rear pinch jaws 852 and 854 are alsowithdrawn from each other to allow the film 812 to pass. In the instanceshown in FIG. 9E, the transverse seal 834 near to the bottom 832 of thebag 826 is approximately at the same level as the front and rear pinchjaws 852 and 854.

From the position shown in FIG. 9E, the film 812 is advanced to theposition shown in FIG. 9F where the front and rear pinch jaws 852 and854 are brought together with the film 812 in between. In FIG. 9F, thedispenser 818 is in the process of dispensing foaming chemicalprecursors 836 into the bag 826. The foaming chemical precursors 836 mayhave begun to mix together and form foam, but they are typically stillin a mostly liquid state. After the foaming chemical precursors 836 aredispensed, the foaming chemical precursors 836 fall to the point shownin FIG. 9G, where the foaming chemical precursors 836 are deterred fromfalling any further by front and rear pinch jaws 852 and 854 that arepinching the film 812. From that location, the foaming chemicalprecursors 836 continue to form foam and to grow in volume.

The front and rear pinch jaws 852 and 854 are then withdrawn from eachother to permit the film 812 to be advanced to the position shown inFIG. 9H. At that point, the front and rear jaw assemblies 828 and 830are brought together with the film 812 in between to form the transversecut and the transverse seals 840 and 846 in the film, 812. In FIG. 9H,as the front and rear jaw assemblies 828 and 830 are forming thetransverse cut and the transverse seals 840 and 846 in the film 812, thefoaming chemical precursors 836 continue to form foam and grow in volumefrom the position inside the bag 826 at which the foaming chemicalprecursors 836 were held in FIG. 9G. In some embodiments, by the timethat the front and rear jaw assemblies 828 and 830 are withdrawn fromeach other, the foaming chemical precursors 836 may have more of theconsistency of foam than liquid such that the foaming chemicalprecursors 836 would not flow like liquid when the front and rear jawassemblies 828 and 830 are withdrawn from each other.

In FIG. 9I, the bag 826 is fully separated from the rest of the film 812and is capable of falling downward (as shown in FIG. 9I) or otherwisemoved away from the rest of the film 812. The front and rear jawassemblies 828 and 830 have been moved away from each other. The frontand rear pinch jaws 852 and 854 have been brought together to pinch thefilm 812 in the subsequent bag 842. The dispenser 818 is also dispensingfoaming chemical precursors 848 into the subsequent bag 842 to fill thesubsequent bag 842 with foam. Although not shown in FIG. 9I, the frontand rear pinch jaws 852 and 854 will deter the foaming chemicalprecursors 848 from falling below the front and rear pinch jaws 852 and854 in the subsequent bag 842. The foaming chemical precursors 836 inthe bag 826 also continue to form foam and grow in volume inside the bag826. In some cases, the foaming chemical precursors 836 are capable offorming foam that occupies a space of several hundreds of times greaterthan the volume of the individual foaming chemical precursors beforethey were mixed.

As can be seen particularly in FIG. 9I, the foam in the bag 826 createdby the foam-in-bag system 850 is more balanced than the foam in the bag826 created by the foam-in-bag system 810. While the foam in the bag 826created by the foam-in-bag system 850 may not have a center of gravityat the exact center of the bag 826 (e.g., the top corners of the bag 826are fuller than the lower corners of the bag 826 in FIG. 9I), the foamis substantially balanced within the bag 826. This balance of the foamin the bag 826 may make the bag 826 more effective for use as aprotection material and may make it easier for the bag 826 to be fitinto a shipping container (e.g., a box) around an object that is locatedin the shipping container.

One benefit of the foam-in-bag system 850 is that the front and rearpinch jaws 852 and 854 can be controlled so that the front and rearpinch jaws 852 and 854 pinch the bags at specific locations. Forexample, the location at which the front and rear pinch jaws 852 and 854pinch a bag may be based on the expected height of the bag. In oneembodiment, the front and rear pinch jaws 852 and 854 may be controlledto pinch the bag at a distance from the bottom of the bag that isapproximately half of the expected height of the bag. In anotherembodiment, the front and rear pinch jaws 852 and 854 may be controlledto pinch the bag at a distance from the bottom of the bag that isapproximately half of the expected height of the bag less some offset.In this last embodiment, the offset may be used to take into account anamount of expected foam formed from the foaming chemical precursorswhile the front and rear pinch jaws 852 and 854 are pinching the film.In other embodiments, the location at which the front and rear pinchjaws 852 and 854 pinch a bag may be based on any other parameter ordesired location of the start of the form formation by the foamingchemical precursors. In addition, the length of time that the front andrear pinch jaws 852 and 854 pinch a bag may be controlled based on adesired dwell time of the foaming chemical precursors before the frontand rear pinch jaws 852 and 854 are withdrawn from each other.

Depicted in FIGS. 9J and 9K are side views of the foam-in-bag system 100having front and rear pinch jaws. More specifically, FIGS. 9J and 9Kdepict sides views of the front and rear pinch jaws in withdrawn andpinched orientations, respectively. In these views, the front pinch jaw852 has an L-shaped cross-section and the rear pinch jaw 854 has acircular cross-section. In other embodiments, the front and rear pinchjaws 852 and 854 may have other cross-sectional shapes. In FIG. 9J, afilm path 856 is depicted showing the expected path of film through thedepicted portion of the foam-in-bag system 100. With the front and rearjaw assemblies 700 and 732 withdrawn from each other and the front andrear pinch jaws 852 and 854 withdrawn from each other in FIG. 9J, thefilm path 856 extends substantially vertically. With the front and rearpinch jaws 852 and 854 moved toward each other to pinch the film in FIG.9K, the film path 856 is a tortuous path through the front and rearpinch jaws 852 and 854. This tortuous path deters liquid from passingbelow the pinched ends of the front and rear pinch jaws 852 and 854.

As shown in FIGS. 9J and 9K, the positions of the front and rear pinchjaws 852 and 854 are controlled by a motor 858. In some embodiments, themotor 858 is a solenoid, an electric motor, or any other actuator. Themotor 858 is coupled to one of the rear pinch jaw 854 by a belt 860.Rotation of the motor 858 causes movement of the belt 860, which resultsin a rotation of the rear pinch jaw 854. In the depicted embodiment, therear pinch jaw 854 is rotationally coupled to the front pinch jaw 852(e.g., via gear teeth) so that rotation of the rear pinch jaw 854 willcause counter rotation of the front pinch jaw 852. In this way,movements of the motor 858 are configured to result in movements of thefront and rear pinch jaws 852 and 854 toward and away from each other.FIGS. 9J and 9K also depict a biasing element 862 that biases the frontand rear pinch jaws 852 and 854 away from each other. In the depictedembodiment, the biasing element 862 is coupled to the front pinch jaw852 to cause it to rotate counterclockwise unless the force of the motor858 overcomes the force of the biasing element 862 to cause the frontand rear pinch jaws 852 and 854 to move toward each other.

Depicted in FIGS. 10A and 10B are perspective and cross-sectional sideviews, respectively, of the foam-in-bag system 810. After the film 812passes the dispenser 818, the two longitudinal edges 816 are broughttogether by the proximal set of rollers 820 and the proximal set ofrollers 820 forms the longitudinal seal 824 in the film 812. As can beseen in FIG. 10B, portions of the two plies of the film 812 can remainseparated in the region between the dispenser 818 and the transverseseal 834. In particular, the two plies of the film 812 can be separatedboth between the proximal and distal sets of rollers 820 and 822 andbetween the front and rear jaw assemblies 828 and 830.

The separation of the two plies of the film 812 below the dispenser 818allows for proper dispensing of foaming chemical precursors 836 into thebag 826. Depicted in FIGS. 10C and 10D are the proper dispensing andfoaming of the foaming chemical precursors 836. In the instance shown inFIG. 10C, the foaming chemical precursors 836 are dispensed by thedispenser 818 and they pass through the two plies of the film 812 untilthe foaming chemical precursors 836 pool at the transverse seal 834. Itshould be noted that a similar proper dispensing may occur in thefoam-in-bag system 850, except that, after the foaming chemicalprecursors 836 are dispensed by the dispenser 818, the foaming chemicalprecursors 836 pass through the two plies of the film 812 until thefoaming chemical precursors 836 pool at the point where the front andrear pinch jaws 852 and 854 pinch the film 812. In the instance shown inFIG. 10D, the film 812 has been advanced downward and the foamingchemical precursors 836 have grown in volume to fill a portion of thebag 826. In FIGS. 10C and 10D, the timing of the dispensing of thefoaming chemical precursors 836, the amount of the foaming chemicalprecursors 836 dispensed, and the advancement of the film 812 arecontrolled so that the foaming chemical precursors 836 remain in the bag826 as the foaming chemical precursors 836 grow in volume.

Under some conditions, the two plies of the film 812 do not remainseparated between the dispenser 818 and the point at which the foamingchemical precursors 836 are intended to pool (e.g., the transverse seal834, the point at which the front and rear pinch jaws 852 and 854 pinchthe film, etc.). In this case, the dispensing and growth of the foamingchemical precursors 836 may result in a “foam-up” failure.

An example of a foam-up failure is depicted in the instances shown inFIGS. 10E and 10F. In FIG. 10E, the two plies of film 812 were notseparated in the region between the proximal and distal sets of rollers820 and 822. This lack of separation may be caused by improper feedingof the film 812, improper driving of the proximal and distal sets ofrollers 820 and 822, impingement on the outside of the film 812 by aforeign object, pulling of the film 812 by a user, or for any otherreason. As can be seen in FIG. 10E, the lack of separation of the twoplies of the film 812 results in the dispensed foaming chemicalprecursors 836 pooling at or above the proximal and distal sets ofrollers 820 and 822. Because the foaming chemical precursors 836 begingrowing from a higher than expected location, the growth in volume ofthe foaming chemical precursors 836 causes the resultant foam to reachtoo high. FIG. 10F shows the growth in volume of the foaming chemicalprecursors 836. As shown in FIG. 10F, the foaming chemical precursors836 reached a height where they contacted the dispenser 818. The foam onthe dispenser 818 hardens and adheres to the dispenser 818 so thatextensive cleaning will be needed to properly use the dispenser 818again. In addition, the foaming chemical precursors 836 reached a heightwhere the two longitudinal edges 816 were not sealed and the foam isable to flow out of the film 812. In this case, the foam can fall onother components of the foam-in-bag system 810, the floor, or anywhereelse. This foam may also need to be cleaned before continuing to use thefoam-in-bag system 810. While the depiction in FIGS. 10E and 10F showsthe two plies of the film 812 failed to separate at the proximal anddistal sets of rollers 820 and 822, the two plies of the film 812 canfail to separate at other locations. For example, the film 812 can beheld together unintentionally by the front and rear jaw assemblies 828and 830, by front and rear pinching jaws, by a user holding the film, orby any other means.

Depicted in FIG. 10G is a front view of a foam-in-bag system 870 thatmay be used to reduce the possibility of a foam-up failure. Thefoam-in-bag system 870 is similar to the foam-in-bag system 810, exceptthat the foam-in-bag system 870 includes proximity sensors 872. Theproximity sensors 872 are oriented downward (as shown by arrows) todetect a distance to an object below the dispenser 818. For example, theproximity sensors 872 may detect a location of foaming chemicaldispensers in the bag 826, a location where the film 812 is closed, or alocation of any other object below the dispenser 818. In the event thatthe proximity sensors 872 detect foaming chemical dispensers growinghigher than expected, a controller (not shown) in the foam-in-bag system870 could cause one or more of stopping the dispensing of the foamingchemical precursors by the dispenser 818, further feeding the film 812to increase the size of the bag 826, or any other action to deter thepossibility of a foam-up failure.

The proximity sensors 872 in the foam-in-bag system 870 may be able toreduce the probability of a foam-up failure. However, the use of theproximity sensors 872 may not be able to detect every potential foam-upcondition. For example, the shape of the top of the contour of the topof the growing foam is different every time that a bag is filled. Insome cases, the contour of the growing foam may allow for a properreading of the distance to the foam by the proximity sensors 872, thusallows for detection of a foam-up failure. However, in other cases, thecontour of the growing foam may not allow for a proper reading of thedistance to the foam by the proximity sensors 872, thus preventingdetection of a foam-up failure. In another example, the consistency ofthe foam may affect the ability of the proximity sensors 872 to detectthe distance to the foam. Foam is inherently porous and, in cases wherethe foam is more porous than normal, the proximity sensors 872 may notdetect the location of the foam. In these cases, the proximity sensors872 may not be able to detect a foam-up failure. In another example, thefilm 812 may interfere with the ability of the proximity sensors 872 todetect the position of the foam. In some cases, one of the plies of film812 may be moved (e.g., blown) into the path between the proximitysensors 872 and the film, which interferes with the ability of theproximity sensors 872 to detect the location of the foam.

Depicted in FIG. 10H is a cross-sectional side view of one embodiment ofa foam-in-bag system 880 capable of detecting foam-up conditions fromoutside of the film 812. The foam-in-bag system 880 includes a source882 of electromagnetic energy 884 located outside of the film 812 andarranged to emit the electromagnetic energy 884 toward the film 812. Insome embodiments, the electromagnetic energy 884 includeselectromagnetic energy having a wavelength in at least one of a range ofvisible light (i.e., having a frequency between about 400 nm and about700 nm), a range of ultraviolet energy (i.e., having a frequency betweenabout 10 nm and about 400 nm), a range below ultraviolet energy (i.e.,having a frequency less than or equal to about 10 nm), a range ofinfrared energy (i.e., having a frequency between about 700 nm and about1 mm), or a range above infrared energy (i.e., having a frequencygreater than or equal to about 1 mm). In some embodiments, the source882 of the electromagnetic energy 884 includes one or more of anincandescent energy source (e.g., an incandescent light bulb, a halogenlamp, etc.), a luminescent energy source (e.g., a light-emitting diode(LED), a laser, etc.), or any other source of electromagnetic energy.

The foam-in-bag system 880 also includes a detector 886 capable ofdetecting electromagnetic energy. The detector 886 is located outside ofthe film 812, on an opposite side of the film 812 from the source 882 ofthe electromagnetic energy 884, and the detector 886 is arranged todetect electromagnetic energy propagating away from the film 812. Insome embodiments, the detector 886 is capable of detectingelectromagnetic energy having a wavelength in at least one of a range ofvisible light, a range of ultraviolet energy, a range below ultravioletenergy, a range of infrared energy, or a range above infrared energy. Insome embodiments, the detector 886 includes a semiconductor-basedphotodetector, such as one or more of a charge-coupled device (CCD), aphotoresistor, a photodiode, a complementary metal-oxide-semiconductor(CMOS) image sensor, or any other semiconductor-based photodetector. Insome embodiments, the detector 886 is configured to detectelectromagnetic energy in a range that includes the electromagneticenergy 884 emitted by the source 882. In some embodiments, the detector886 is configured to detect electromagnetic energy in a range that doesnot include the electromagnetic energy 884 emitted by the source 882.

In the embodiment depicted in FIG. 10H, the source 882 of theelectromagnetic energy 884 and the detector 886 are located verticallybetween the dispenser 818 and the proximal and distal sets of rollers820 and 822. In other embodiments, the source 882 of the electromagneticenergy 884 and the detector 886 can be located vertically at differentlocations, such as vertically between the proximal and distal sets ofrollers 820 and 822 and the front and rear jaw assemblies 828 and 830,below the front and rear jaw assemblies 828 and 830, or in any otherlocation. From the view shown in FIG. 10H, the source 882 of theelectromagnetic energy 884 shows one LED located on the rear side of thefilm 812 and the detector 886 shows one photodetector located on thefront side of the film 812. In some embodiments, the source 882 of theelectromagnetic energy 884 may include a single source, such as one LED,and the detector 886 may include a single detector, such as onephotodetector. In other embodiments, the source 882 of theelectromagnetic energy 884 may include a number of distinct sources,such as a number of LEDs that are arranged across a transverse width ofthe film 812, and the detector 886 may include a number of distinctdetectors, such as a number of photodetectors that are arranged across atransverse width of the film 812. In other embodiments, the source 882of the electromagnetic energy 884 may include a single source and thedetector 886 may include a number of distinct detectors. In otherembodiments, the source 882 of the electromagnetic energy 884 mayinclude a number of sources and the detector 886 may include a singledetector.

In some embodiments, film 812 is transmissive of at least a portion ofthe electromagnetic energy 884 emitted by the source 882. For example,the electromagnetic energy 884 may include infrared energy and the film812 may be transmissive of electromagnetic energy in the range ofinfrared energy. In addition, the foam, which is formed by the foamingchemical precursors that are dispensed into the bag 826, may be opaqueto portion of the electromagnetic energy 884 emitted by the source 882.For example, the electromagnetic energy 884 may include infrared energyand the foam may be opaque to electromagnetic energy in the range ofinfrared energy.

As used herein, the term “opaque” and “transmissive” may be defined interms of one or more of total luminous transmittance, opacity, orcontrast ratio opacity. Total luminous transmittance may be defined asthe percentage of luminous flux that passes through an object whenelectromagnetic energy (e.g., visible light) is transmitted at theobject. In some embodiments, an object is opaque if the object has atotal transmittance that is at or below any one of the following values:10%, 20%, 30%, 40%, 50%, 60%, 65%, 70%, 75%, 80%, 85%, and 90%, measuredin accordance with ASTM D1003. In some embodiments, an object istransmissive if the object has a total luminous transmittance that is ator above any one of the following values: 10%, 20%, 30%, 40%, 50%, 60%,65%, 70%, 75%, 80%, 85%, and 90%, measured in accordance with ASTMD1003. Opacity may be defined as the percentage of luminous flux thatdoes not pass through a film when electromagnetic energy is transmittedat the film. Opacity may be defined according to the formula 100%−totaltransmittance=opacity. In some embodiments, an object is opaque if theobject has an opacity that is at or above any one of the followingvalues: 10%, 20%, 30%, 40%, 50%, 60%, 65%, 70%, 75%, 80%, 85%, and 90%.In some embodiments, an object is transmissive if the object has anopacity that is at or below any one of the following values: 10%, 20%,30%, 40%, 50%, 60%, 65%, 70%, 75%, 80%, 85%, and 90%. Contrast ratioopacity measurement characterizes how opaque an object is using tworeadings: a Y (luminance or brightness) value measured with the objectbacked by a black background and a Y value measured with the objectbacked by a white background. The resulting fraction is expressed as Y%, calculated as follows:

${{Opacity}\mspace{11mu} (Y)} = {\frac{Y_{{black}\mspace{14mu} {backing}}}{Y_{{white}\mspace{14mu} {backing}}} \times 100}$

In some embodiments, an object is opaque or transmissive if the contrastratio opacity for the film is at least, and/or at most, any one of thefollowing values: 10%, 20%, 30%, 40%, 50%, 60%, 65%, 70%, 75%, 80%, 85%,and 90%, calculated per above with base values measured in accordancewith ASTM D1746.

As noted above, in some embodiments, the electromagnetic energy 884emitted by the source 882 may include ultraviolet electromagnetic energyand the film 812 may be transmissive to the ultraviolet electromagneticenergy in the electromagnetic energy 884. In the arrangement shown inFIG. 10H, the detector may detect an amount of ultravioletelectromagnetic energy. It should be noted that the intensity of theultraviolet electromagnetic energy detected by the detector 886 may beless than the intensity of the ultraviolet electromagnetic energyemitted by the source 882, in part because the film 812 may betransmissive while having a total transmittance of ultravioletelectromagnetic energy that is less than 100%. In the instance shown inFIG. 10I, a foam-up failure has begun with the foaming chemicalprecursors 836 pooling at the proximal and distal sets of rollers 820and 822 and the foam growing from that point. The foam may be opaquesuch that the intensity of ultraviolet electromagnetic energy detectedby the detector 886 is less than it detected in FIG. 10H. In should benoted that the level of intensity of the ultraviolet electromagneticenergy detected by the detector 886 may not go to zero, in part becausethe foam may be opaque while having a total transmittance of ultravioletelectromagnetic energy that is greater than 0%.

The foam-in-bag system 880 may include a controller (not shown) that isoperatively coupled to the detector 886 and configured to receivesignals from the detector 886 indicative of an intensity ofelectromagnetic energy. The controller may detect the reduction in theintensity of the electromagnetic energy detected by the detector 886and, in response, cause actions to avoid a foam-up condition or toreduce the effects of a foam-up condition. For example, the controllermay cause one or more of stopping the dispensing of the foaming chemicalprecursors by the dispenser 818 and/or further feeding the film 812 toincrease the size of the bag 826. In some cases, the controller may beable to detect a potential foam-up condition based on a geometry of thestream of foaming chemical precursors 836 being dispensed by thedispenser 818. In this example, the source 882 of the electromagneticenergy 884 and the detector 886 may be aligned with the stream of thefoaming chemical precursors 836 being dispensed by the dispenser 818 sothat the signals generated by the detector 886 are indicative of thegeometry of the stream of the foaming chemical precursors 836 beingdispensed by the dispenser 818.

In some embodiments, foam-in-bag systems include one or more userinterface devices to enable a user to interact with the foam-in-bagsystem. A user interface device can include a user input device thatreceives user inputs, a user output device that outputs information to auser, or a user input/output device that can both receive user input andoutput information (e.g., a touchscreen device). Depicted in FIGS. 11Aand 11B are views of an embodiment of the foam-in-bag system 100 thatincludes user interface devices 910 and 912. The user interface devices910 and 912 can receive inputs from a user, such as indications of howbags are to be created (e.g., bag widths, bag lengths, seal strengths,etc.), how bags are to be filled (e.g., an amount of foaming chemicalprecursors to be dispensed, where in the bags the foaming chemicalprecursors to be dispensed, etc.), how many bags are to be created, andthe like. The user interface devices 910 and 912 can output informationto a user, such as indications about statuses of the foam-in-bag system100 (e.g., in idle mode, in proper operating mode, in error mode, etc.),and the like.

In the depicted embodiment, the user interface device 910 is a discreteuser interface device in the form of a tablet computing device. The userinterface device 910 is discrete in the sense that it is located on thefoam-in-bag system 100 in such a way that it is capable of being removedfrom the foam-in-bag system 100 while the foam-in-bag system 100 remainsusable to form and fill bags. In the depicted embodiment, the userinterface device 912 is an integrated user interface device in the formof a projective capacitance touchscreen and lights on the face of thefront lower cover 512. The user interface device 912 is discrete in thesense that it is located on the foam-in-bag system 100 in such a waythat it is intended to remain a part of the foam-in-bag system 100 whilethe foam-in-bag system 100 remains usable. In some embodiments, theexterior of the user interface device 912 and/or the face of the frontlower cover 512 is made from a material that tends not to adhere toother materials and that is highly non-porous. In these embodiments, ifresin and/or chemical foaming precursors that fall on the exterior ofthe user interface device 912 and/or the face of the front lower cover512, the resin and/or chemical foaming precursors tend not to stick tothe exterior of the user interface device 912 and/or the face of thefront lower cover 512.

In some embodiments, each of the user interface devices 910 and 912 iscommunicatively coupled to a computing device inside the foam-in-bagsystem 100, such as a controller. The controller may be capable ofcontrolling one or more components of the foam-in-bag system 100, suchas the dispenser 174, the proximal and distal driven rollers 520 and522, longitudinal sealer 538, and the like. In this example, inputs intoone or both of the user interface devices 910 and 912 can becommunicated to the controller and, in response, the controller cancontrol the foam-in-bag system 100. In some embodiments, the controllerincludes circuitry in one or more printed circuit boards, softwareoperating on the one or more printed circuit boards, or any combinationthereof. In some embodiments, when one of the user interface devices 910and 912 is used to provide a user input to control the foam-in-bagsystem 100, a corresponding output may be provided on both of the userinterface devices 910 and 912. For example, the user interface device912 may have a button that can be pressed to cause the foam-in-bagsystem 100 to operate under preset conditions. When a user presses thebutton on the user interface device 912, a corresponding light may beilluminated to provide an output to the user indicating that the presetconditions have been selected. In other embodiments, other feedback maybe provided to a user, such as auditory feedback (e.g., a sound),tactile responses (e.g., a vibration), haptic responses, and the like.The user interface device 910 may also display a button on a touchscreenthat can be selected to cause the foam-in-bag system 100 to operateunder the preset conditions. When the user presses the button on theuser interface device 912, the corresponding button on the userinterface device 910 may be highlighted to provide an output to the userindicating that the preset conditions have been selected. Other forms ofuser input are possible, such as a microphone that detects audiblespeech from a user that is processed to determine user commands givenorally.

In some embodiments, one or both of the user interface devices 910 and912 can serve as the controller that controls one or more components ofthe foam-in-bag system 100. In one example, it may be beneficial to havea discrete user interface device (e.g., user interface device 910) serveas the controller because it is relatively easy to remove and replacethe user interface device 910 when desired, such as when it is desirableto upgrade the user interface device 910 with a new user interfacedevice but the remainder of the components of the foam-in-bag system 100do not need to be replaced. In another example, it may be advantageousto allow a user to control the foam-in-bag machine 100 remotely using aremote computing device, such as a mobile phone, a laptop computer at aremote work station, and the like. It may easier to configure a discreteuser interface device (e.g., user interface device 910) to communicatewith a remote computing device via one or more wireless or wiresnetworks (e.g., via a WiFi network, a cellular telephone network, alocal area network, etc.) than to configure an integrated user interfacedevice to communicate with the remote computing device. In thisinstance, it may be desirable to configure the discrete user interfacedevice to both communicate with the remote computing device and tocontrol the foam-in-bag system 100 based on the communications from theremote computing device.

Existing foam-in-bag systems include discrete user interface devices.However, these foam-in-bag systems are fixedly attached to the housingsof these existing foam-in-bag systems. Having a discrete user interfacedevice fixedly attached to a housing of a foam-in-bag system may beproblematic. For example, the discrete user interface device may belocated where it does not fit with other equipment placed around thefoam-in-bag system (e.g., in a packaging line). In another example, thediscrete user interface device is located in an inconvenient locationfor the user (e.g., on the right side of the foam-in-bag system for aleft handed user). In the embodiment depicted in FIGS. 11A and 11B, theuser interface device 910 is capable of being repositioned in differentlocations. In the instance shown in FIG. 11A, the user interface device910 is located on the right side of the foam-in-bag system 100. In theinstance shown in FIG. 11B, the user interface device 910 is located onthe left side of the foam-in-bag system 100. In some embodiments, theuser interface device 910 includes one or more sensors (e.g., agyroscope, an accelerometer, a hall effect sensor, etc.) that allow theuser interface device to determine its orientation and adjust theorientation of feedback to the user (e.g., the orientation of graphicson a screen) accordingly. In some embodiments, a user is able toreposition the user interface device 910 between the positions shown inFIGS. 11A and 11B by hand without the use of tools. In some embodiments,the user interface device 910 is located on an arm that is capable ofbeing rotated 180° to reposition the user interface device 910 betweenthe positions shown in FIGS. 11A and 11B. An example of such an arm 920is depicted in FIGS. 11C to 11E.

In the embodiment depicted in FIG. 11C, the arm 920 includes a first armsegment 922 and a second arm segment 924. The first arm segment 922 isrotatably coupled to a bracket 926 on the back of the housing 194. Inthe depicted example, the first arm segment 922 is rotatably coupled tothe bracket 926 by a pin 928 so that the first arm segment 922 rotatesabout an axis that is substantially parallel to the ground andsubstantially perpendicular to the front of the foam-in-bag system 100.This permits the first arm segment 922 to rotate between a horizontalposition where the first arm segment 922 is engaged by a first positionbracket 930 and another horizontal position where the first arm segment922 is engaged by a second position bracket 932.

In some embodiments, the arm 920 is arranged so that the first armsegment 922 is configured to remain engaged in each of the first andsecond position brackets 930 and 932. In some embodiments, the first armsegment 922 is biased toward one of the first and second positionbrackets 930 until a force is exerted on the arm 920 by a user. Thefirst arm segment 922 can be biased toward one of the first and secondposition brackets 930 by a magnetic force, by a mechanical force, by anyother force, or by any combination of forces. In the embodiment shown inFIGS. 11C to 11E, first arm segment 922 is biased toward one of thefirst and second position brackets 930 and 932 by a combination ofmagnetic force and mechanical force.

In some embodiments, the first arm segment 922 can be configured toremain engaged in each of the first and second position brackets 930 and932 by a magnetic force. In the depicted embodiment, the first positionbracket 930 may include a magnet (e.g., a permanent magnet or anelectromagnet) and the first arm segment 922 may include a magneticmaterial. When the first arm segment 922 engages the first positionbracket 930, the magnetic force between the magnet and the first armsegment 922 deters the first arm segment 922 from disengaging from thefirst position bracket 930 until a user presses down on the arm 920 withsufficient force to overcome the magnetic force. Similarly, the secondposition bracket 932 may include a magnet (e.g., a permanent magnet oran electromagnet) and the first arm segment 922 may include a magneticmaterial. When the first arm segment 922 engages the second positionbracket 932, the magnetic force between the magnet and the first armsegment 922 deters the first arm segment 922 from disengaging from thesecond position bracket 932 until a user presses down on the arm 920with sufficient force to overcome the magnetic force.

In some embodiments, the first arm segment 922 can be configured toremain engaged in each of the first and second position brackets 930 and932 by a mechanical force. In the depicted embodiment, the arm 920includes a biasing mechanism 934 configured to bias the first armsegment 922 toward one of the first and second position brackets 930 and932. The depicted biasing mechanism 934 is rotatably coupled to abracket 936 that is fixedly coupled to the housing 194. The biasingmechanism 934 is also rotatably coupled to a portion of the first armsegment 922 that is on an opposite side of the pin 928 from the portionof the first arm segment 922 that engages the first and second positionbrackets 930 and 932. In this arrangement, the biasing mechanism 934exerts a mechanical force on the first arm segment 922 that biases thefirst arm segment 922 to rotate about the pin 928. For example, when thefirst arm segment 922 is in the position shown in FIG. 11C, the biasingmechanism 934 exerts a downward force on the portion of the first armsegment 922 on the right side of the pin 928, which biases the first armsegment 922 to rotate clockwise until the first arm segment 922 hits thefirst position bracket 930. Similarly, the first arm segment 922 can berotated counterclockwise from the position shown in FIG. 11C until thefirst arm segment 922 is on the other side of vertical. At that point,the biasing mechanism 934 would exerts a downward force on the portionof the first arm segment 922 on the left side of the pin 928, whichwould bias the first arm segment 922 to rotate counterclockwise untilthe first arm segment 922 hits the second position bracket 932. In thedepicted embodiment, the biasing mechanism 934 is a compression gasspring. In other embodiments, the biasing mechanism 934 could be anyother type of spring or any other type of biasing mechanism 934.

The ability of the first arm segment 922 to rotate between the first andsecond position brackets 930 and 932 permits the user interface device910 to be repositioned between at least two distinct positions. Forexample, the rotation of the first arm segment 922 can permit the userinterface device 910 to be repositioned at positions on the left andright sides of the foam-in-bag system 100, as shown in FIGS. 11A and11B. In some embodiments, a user is able to reposition the userinterface device 910 between the positions by hand without the use oftools. In addition to being able to reposition the user interface device910 on the left and right sides of the foam-in-bag system 100, theembodiment of the arm 920 also permits vertical adjustment of the userinterface device 910 in both positions on the left and right sides ofthe foam-in-bag system 100. The vertical adjustment of the userinterface device 910 when the user interface device 910 is positioned onthe right side of the foam-in-bag system 100 is depicted in FIGS. 11Dand 11E.

In the depicted embodiment, the arm 920 is configured to permit verticaladjustment of the user interface device 910 by adjustment of the secondarm segment 924. In particular, the second arm segment 924 is rotatablycoupled to the first arm segment 922. In the depicted embodiment, whenthe first arm segment 922 is engaged to one of the first and secondposition brackets 930 and 932, the second arm segment 924 is capableabout an axis that is substantially parallel to the ground andsubstantially parallel to the front of the foam-in-bag system 100. Thesecond arm segment 924 is also rotatably coupled to the user interfacedevice 910. In the depicted embodiment, the second arm segment 924includes two separate bars, each of which is rotatably coupled to thefirst arm segment 922 and rotatably coupled to the user interface device910. The two-bar embodiment of the second arm segment 924 ensures thatrotation of the second arm segment 924 about the first arm segment 922will cause a corresponding rotation of the second arm segment 924 aboutthe user interface device 910 such that the front of the user interfacedevice 910 stays substantially vertical. In the depicted embodiment, thearm 920 includes a latching bracket 938 configured to selectively holdthe two bars of the second arm segment 924. The latching bracket 938 maybe configured to hold the two bars of the second arm segment 924 withrespect to each other unless a user activates a disengagement mechanism(e.g., the user squeezes a disengagement lever). In this way, the usercan activate the disengagement mechanism on the latching bracket 938 topermit vertical adjustment of the user interface device 910 and then theuser can release the disengagement mechanism to hold the verticalposition of the user interface device 910. In the depicted embodiment,the arm 920 is capable of vertically positioning the user interfacedevice 910 between a lower vertical position shown in FIG. 11D and anupper vertical position shown in FIG. 11E.

In some embodiments, the second arm segment 924 is rotatably coupled tothe user interface device 910 about two axes. In addition to therotation of the second arm segment 924 with respect to the userinterface device 910 that permits the vertical repositioning of the userinterface device 910 shown in FIGS. 11D and 11E, the second arm segment924 may also permit rotation of the user interface device 910 about avertical axis. This permits a user to rotate the user interface device910 so that the front of the user interface device 910 is angled eithermore toward the center of the foam-in-bag system 100 or away from thecenter of the foam-in-bag system 100.

Depicted in FIGS. 12A and 12B are views of the foam-in-bag system 100 inlowered and raised positions, respectively. In the embodiment shown inFIGS. 10A and 10B, the housing 194 of the foam-in-bag system 100includes a base 1010 and a stem 1012. The base 1010 is configured to beplaced on a surface, such as a floor. The stem 1012 is configured tosupport portions of the foam-in-bag system 100 that are located abovethe base 1010. In the depicted embodiment, the stem 1012 is located onthe left side of the foam-in-bag system 100. This location of the stem1012 may accommodate a packaging line or other equipment to pass beneaththe portions of the foam-in-bag system 100 that are supported by thestem 1012.

The stem 1012 includes a movable support 1014. In the depictedembodiment, the movable support 1014 is configured to be movedvertically up and down. Portions of the foam-in-bag system 100 arecoupled to the movable support 1014 so that they move vertically up anddown with the movable support 1014. In the depicted embodiment, thespindle system 402 is coupled to the movable support 1014 so that thespindle system 402 moves vertically with the movable support 1014. Whenthe roll 400 is on the spindle system 402, the roll 400 also movesvertically with the movable support 1014. The front upper and lowercovers 510 and 512 are also coupled to the movable support 1014 so thatthe front upper and lower covers 510 and 512 move vertically with themovable support 1014. The components of the foam-in-bag system 100behind of the front upper and lower covers 510 and 512—including thosethat feed and film from the roll 400, form bags from the film, anddispense chemical precursors into the bags—also move vertically with themovable support 1014. The user interface device 910 is also coupled tothe movable support 1014. In some embodiments, the arm 920 is coupled toa portion of the housing 194 that moved vertically with the movablesupport 1014 so that the user interface device 910 also moves verticallywith the movable support 1014. While the components of the foam-in-bagsystem 100 mentioned here are coupled to the movable support 1014 in thedepicted embodiment, it will be understood that other components of thefoam-in-bag system 100 may also be coupled to the movable support 1014and, in other embodiments, not all of the components mentioned here willbe coupled to the movable support 1014.

The movable support 1014 is capable of being moved vertically betweenthe lowered position shown in FIG. 12A and the raised position shown inFIG. 12B. In some embodiments, the vertical position of the movablesupport 1014 can be controlled so that the movable support can belocated at the lowered position, at the raised position, or at anyposition therebetween. The vertical position of the movable support 1014can be selected based on operating conditions around the foam-in-bagsystem 100 (e.g., a desired vertical location of the formed bags to bedischarged, an accommodation for equipment around the foam-in-bag system100), based on servicing needs (e.g., a desired vertical location of thespindle system 402 to replace the roll 400), or based on any otherdesired vertical location.

Existing foam-in-bag systems are capable of moving portions of thesystems vertically. In some examples, these existing foam-in-bag systemsinclude a motor that provides the force to lift all of thevertically-movable components. However, the sum of the weight of thevertically-movable components may be greater than 100 pounds. In theseexisting systems, the motors needed to provide significant force to movethe vertically-movable components. Motors with these capabilities can bedifficult to control when it comes to fine adjustments of verticalpositions. In addition, the amount of force applied by the motor couldcause serious damage or injury to users of the foam-in-bag systems.

Depicted in FIG. 12C is an embodiment of the foam-in-bag system 100 thatincludes a vertical counterbalance 1016 in the stem 1012. The verticalcounterbalance 1016 is configured to exert a force between the base 1010and the movable support 1014. The force exerted by the verticalcounterbalance 1016 offsets the weight of the movable support 1014 andthe components that are supported by the movable support 1014. In thedepicted embodiment, the vertical counterbalance 1016 is a gas spring.In other embodiments, the vertical counterbalance 1016 may be acompression spring or any other device that is capable of applying anupward force to the movable support 1014.

In some embodiments, at least one characteristic of the verticalcounterbalance 1016 is selected based on an expected weight of themovable support 1014 and the components that are supported by themovable support 1014. For example, the amount of force applied by thevertical counterbalance 1016 may be selected based on an expected weightof the movable support 1014. It should be noted that the weight of thecomponents that are supported by the movable support 1014 will not beconstant during operation. In one example, the weight when the roll 400is full will be significantly different than the weight of the when theroll 400 is empty, and that weight will vary over time as the roll 400is emptied. In another example, the weight of the roll 400 when the filmis wide will be significantly different than the weight of the roll 400when the film is narrow. Because the weight of the components supportedby the movable support 1014 is variable, the amount of force applied bythe vertical counterbalance 1016 may not compensate for the exact weightof the movable support 1014 and the components supported by the movablesupport 1014. Despite this variability, the amount of force applied bythe vertical counterbalance 1016 may still be selected based on anexpected weight of the movable support 1014 and the components supportedby the movable support 1014. For example, the amount of force applied bythe vertical counterbalance 1016 may still be based on one or more of aminimum expected weight of the movable support 1014 and the componentssupported by the movable support 1014, an average expected weight of themovable support 1014 and the components supported by the movable support1014, a maximum expected weight of the movable support 1014 and thecomponents supported by the movable support 1014, or any other valuebased on the expected weight of the movable support 1014 and thecomponents supported by the movable support 1014.

The foam-in-bag system 100 in FIG. 12C also includes a motor 1018configured to impart a force on the movable support 1014 to move themovable support 1014 vertically up and down. Because of the forceimparted by the vertical counterbalance 1016 offsets the force of theweight of the movable support 1014 and the components supported by themovable support 1014, the motor 1018 does not need to provide as muchforce as would be required without the vertical counterbalance 1016.Because of the lower power requirements of the motor 1018, the motor1018 may be less expensive and have lower power demands that would berequired without the vertical counterbalance 1016. In addition, runningthe motor 1018 at lower power increases safety for a user using thefoam-in-bag system 100. For example, if the user's hand is in the way ofthe movable support 1014 as the movable support 1014 is being raised bythe motor 1018, the motor 1018 running at lower power and supplyinglower force will have less of a chance of harming the user's hand thanif the motor 1018 was running at higher power and supplying higherforce. The use of the vertical counterbalance 1016 may also allow forthe movable support 1014 to be moved more quickly while remaining safefor user operation. For example, when a vertical counterbalance is notused, a motor may only be able to raise and lower a movable stand at arate of 0.5 inches per second or less while supplying a torque that iswithin an acceptable safety range. In contrast, when the verticalcounterbalance 1016 is used, the motor 1018 may be able to raise andlower the movable support 1014 at a rate of up to 5 inches per secondwhile supplying a torque that is within an acceptable safety range.

In some embodiments, the motor 1018 may be able to operate in alow-torque mode and in a high-torque mode. In the low-torque mode, themotor 1018 may be operative to move the movable support 1014 verticallywith the assistance of the vertical counterbalance 1016. The amount oftorque that the motor 1018 is able to produce in low-torque mode may bewithin a range that is an acceptable safety range for normal operation.However, the amount of torque produced by the motor 1018 in low-torquemode may not be sufficient to move the movable support 1014 verticallywithout the assistance of the vertical counterbalance 1016. In thehigh-torque mode, the motor 1018 may be able to move the movable support1014 vertically either with or without the assistance of the verticalcounterbalance 1016. The amount of torque that the motor 1018 is able toproduce in high-torque mode may exceed an acceptable safety range fornormal operation, but may be acceptable for specialized operation (e.g.,during servicing of the foam-in-bag system). In some embodiments, themotor 1018 can be switched between the low-torque and high-torque modesby a physical switch associated with the motor 1018. The physical switchcan be covered in normal operation by housing 194, but also beaccessible by removing a portion of the housing 194 (e.g., a panel). Inthis way, the motor 1018 can be set to low-torque mode for normaloperation so that the torque produced by the motor 1018 is within anacceptable safety range during normal operation, but the physical switchcan also be accessed when needed to switch to change to high-torque modeby a specialized user (e.g., a service technician). This dual-modeability of the motor 1018 can be useful in certain situations, such asif the vertical counterbalance 1016 fails and needs to be replaced. Inthe event of the vertical counterbalance 1016 failing, the motor 1018can be switched to high-torque mode by a service technician so thatmovable support 1014 can be moved vertically while the servicetechnician replaces the vertical counterbalance 1016 and then returnedto low-torque mode for normal operation after the verticalcounterbalance 1016 has been replaced.

One difficulty with existing foam-in-bag systems that are capable ofvertical movement is the way in which their vertical movement isactivated. Some existing foam-in-bag systems have easily-activatedmechanisms, such as switches or buttons on the exterior of theirhousings. However, easily-activated mechanisms can be problematicbecause they can be inadvertently activated to move portions of thefoam-in-bag systems. At best, inadvertent movements of a foam-in-bagsystem can be an annoyance or hinderance to those using the systems; atworse, inadvertent movements of a foam-in-bag system can result indamage or injury to an operator, to the foam-in-bag systems themselves,or to other equipment near the foam-in-bag systems. Other existingfoam-in-bag systems include software functionality in a user interfacedevice that allows a user to provide inputs to raise or lower theportions of the foam-in-bag systems. Where the controls are included insoftware functionality, the user interface does not always make thecontrols readily available to the user, sometimes requiring the user tonavigate through multiple screens or menus to be able to control thevertical positioning of the foam-in-bag systems.

Depicted in FIGS. 12D and 12E are front and back views, respectively, ofan embodiment of the user interface device 910 with controls to raiseand lower the movable support 1014. In the depicted embodiment, the userinterface device 910 includes a touchscreen display 1030 configured todisplay information to a user and to receive inputs from a user. Theuser interface device 910 includes a housing 1032 that is located aroundthe touchscreen display 1030 on the front of the user interface device910, as shown in FIG. 12D, and located over most of the back of the userinterface device 910, as shown in FIG. 12E. In the depicted embodiment,the user interface device 910 includes a button 1034 on the front of thehousing 1032. The button 1034 may be a hard button (e.g., a mechanicalbutton), or a soft button (e.g., a touch-sensitive area of the housing1032), or any other type of button. The user may provide inputs to theuser interface device 910 by pressing the button 1034.

As shown in FIG. 12D, the depicted embodiment of the user interfacedevice 910 include a first vertical input device 1036 and a secondvertical input device 1038. The first and second vertical input devices1036 and 1038 are configured to receive user inputs to control verticalmovements of the movable support 1014. When the user interface device910 is in the orientation shown in FIG. 12D, any user input into thefirst vertical input device 1036 can be treated as an input to raise themovable support 1014, and any user input into the second vertical inputdevice 1038 can be treated as an input to lower the movable support1014. If the user interface device 910 is reoriented (e.g., the userinterface device 910 is located on an arm (e.g., the arm 920) that canbe rotated 180°, the user interface device 910 may be oriented such thatthe second vertical input device 1038 is positioned above the button1034 and the first vertical input device 1036 is positioned below thebutton 1034. In this orientation, any user input into the secondvertical input device 1038 can be treated as an input to raise themovable support 1014, and any user input into the first vertical inputdevice 1036 can be treated as an input to lower the movable support1014.

Returning to the orientation shown in FIG. 12D, each of the first andsecond vertical input devices 1036 and 1038 includes directionalindicators. More specifically, the first vertical input device 1036includes a number of directional indicators 1040 ₁, 1040 ₂, 1040 ₃, and1040 ₄ (collectively, directional indicators 1040) and the secondvertical input device 1038 includes a number of directional indicators1042 ₁, 1042 ₂, 1042 ₃, and 1042 ₄ (collectively, directional indicators1042). In the depicted embodiment, the directional indicators 1040 and1042 are graphics printed or adhered onto a touch-sensitive portion ofthe housing 1032. In other embodiments, each of the directionalindicators 1040 and 1042 is a separate hard button or other user inputdevice. In the depicted embodiment, the first vertical input device 1036includes four distinct directional indicators 1040 and the secondvertical input device 1038 includes four distinct directional indicators1042. In other embodiments, the first vertical input device 1036 mayinclude any other number of distinct directional indicators 1040 and thesecond vertical input device 1038 may include any other number ofdistinct directional indicators 1042. In other embodiments, each of thefirst vertical input device 1036 and the second vertical input device1038 includes a single directional indicator that has a gradient (e.g.,a color gradient) indicating a direction.

When the user interface device 910 is in the orientation shown in FIG.12D, a user can press the first vertical input device 1036 to activatethe motor 1018 to cause the movable support 1014 to move upward.Similarly, a user can press the second vertical input device 1038 toactivate the motor 1018 to cause the movable support 1014 to movedownward. In some embodiments, the farther away from a horizontal center1038 of the user interface device 910 that a user presses on one of thefirst and second vertical input devices 1036 and 1038, the faster themotor 1018 to cause the movable support 1014 to move upward or downward.In one example, pressing on the first vertical input device 1036 at thedirectional indicator 1040 ₁ causes the motor 1018 to move the movablesupport 1014 upward at a low speed and pressing on the first verticalinput device 1036 at the directional indicator 1040 ₄ causes the motor1018 to move the movable support 1014 upward at a high speed. Pressingon the first vertical input device 1036 at the directional indicator1040 ₂ causes the motor 1018 to move the movable support 1014 upward ata higher speed than when the directional indicator 1040 ₁ is pressed.Pressing on the first vertical input device 1036 at the directionalindicator 1040 ₃ causes the motor 1018 to move the movable support 1014upward at higher speed than when the directional indicator 1040 ₂ ispressed and at a slower speed than when the directional indicator 1040 ₄is pressed. In another example, pressing on the second vertical inputdevice 1038 at the directional indicator 1042 ₁ causes the motor 1018 tomove the movable support 1014 downward at a low speed and pressing onthe second vertical input device 1038 at the directional indicator 1042₄ causes the motor 1018 to move the movable support 1014 downward at ahigh speed. Pressing on the second vertical input device 1038 at thedirectional indicator 1042 ₂ causes the motor 1018 to move the movablesupport 1014 downward at a higher speed than when the directionalindicator 1042 ₁ is pressed. Pressing on the second vertical inputdevice 1038 at the directional indicator 1040 ₃ causes the motor 1018 tomove the movable support 1014 downward at higher speed than when thedirectional indicator 1042 ₂ is pressed and at a slower speed than whenthe directional indicator 1042 ₄ is pressed.

As noted above, having an easily-activated mechanism to move the movablesupport 1014 may be problematic if the mechanism is able to beinadvertently activated. In the embodiment shown in FIG. 12D, a user maybe able to inadvertently touch the first and second vertical inputdevices 1036 and 1038, particularly when touching the touchscreendisplay 1030 or adjusting a position of the user interface device 910with respect to the foam-in-bag system 100. The embodiment of the userinterface device 910 shown in FIGS. 12D and 12E can reduce inadvertentinputs into the first and second vertical input devices 1036 and 1038using a touch-sensitive area 1044 on the back of the user interfacedevice 910. In some embodiments, an input into one of the first andsecond vertical input devices 1036 and 1038 does not result in movementof the movable support 1014 unless the touch-sensitive area 1044 alsoregisters a corresponding touch on the back of the user interface device910. An example of this is shown in FIG. 12F, where a user's hand 1050is grasping or pinching the right side of the user interface device 910with the user's thumb 1052 touching the second vertical input device1038 on the front of the user interface device 910 and the user's finger1054 touching the touch-sensitive area 1044 on the back of the userinterface device 910. By requiring both an input into one of the firstand second vertical input devices 1036 and 1038 and a touch of thetouch-sensitive area 1044 to move the movable support 1014, the userwill not be able to inadvertently activate motion of the movable support1014 merely by touching one of the first and second vertical inputdevices 1036 and 1038.

In the embodiment depicted in FIG. 12E, the touch-sensitive area 1044 isa single touch-sensitive strip adhered to the back of the user interfacedevice 910. In other embodiments, the touch-sensitive area 1044 mayinclude multiple distinct touch-sensitive areas. In other embodiments,the touch-sensitive area 1044 is an integrated part of the housing 1032(e.g., a part molded into the plastic that forms the housing 1032). Inother embodiments, the touch-sensitive area 1044 is a portion of thehousing 1032 where one or more pressure sensors inside of the userinterface device 910 are capable of detecting pressure applied to thatportion of the housing 1032. In some embodiments, the touch-sensitivearea 1044 is positioned to be substantially aligned with the first andsecond vertical input devices 1036 and 1038 (e.g., the touch-sensitivearea 1044 is approximately behind the first and second vertical inputdevices 1036 and 1038). In some embodiments, the touch-sensitive area1044 is configured to register a touch from any contact. For example, inthe embodiment where the touch-sensitive area 1044 is a capacitive touchsurface, any touch of an electrical counductor (e.g., the user's thumb1052 or the user's finger 1054) may be register as a touch. In otherembodiments, the touch-sensitive area 1044 is configured to register atouch when at least a predetermined force is applied to thetouch-sensitive area 1044. For example, where the touch-sensitive area1044 is a portion of the housing 1032 and one or more pressure sensorsinside of the user interface device 910 are capable of detectingpressure applied to that portion of the housing 1032, a predeterminedamount of pressure may need to be applied to the touch-sensitive area1044 in order to register a touch of the touch-sensitive area 1044. Inthis last example, the predetermined amount of pressure may be a minimumexpected amount of pressure when a user grasps or pinches the side ofthe user interface device 910 with the first and second vertical inputdevices 1036 and 1038.

In some embodiments, detected aspects of a user's behavior may be usedto control the movement of the movable support 1014. In someembodiments, the user interface device 910 includes an accelerometer andbehavior detected by the accelerometer may be used to control themovement of the movable support 1014. For example, when a user isgrasping or pinching the first vertical input device 1036 and thetouch-sensitive area 1044, the movable support 1014 may be moved upward.As the movable support 1014 may be moved upward, the user mayinstinctively pull up on the user interface device 910 when an increasein speed is desired or pull down on the user interface device 910 when adecrease in speed is desired. The accelerometer in the user interfacedevice 910 may detect a pull up or a pull down and adjust the speed ofthe movement of the movable support 1014 accordingly. In someembodiments, the amount of pressure applied by the user to grasp orpinch the user interface device 910 may be used to control the movementof the movable support 1014. In one example, when the user pinches thefirst vertical input device 1036 and the touch-sensitive area 1044, themovable support 1014 may be moved at a particular speed when the amountfor force from the user's pinch is below a predetermined amount ofpressure and the movable support 1014 may be moved at a higher speedwhen the amount of force from the user's pinch is above thepredetermined amount of pressure. In other embodiments, any combinationof registering a grasp or pinch (e.g., detecting an input into one ofthe first and second vertical input devices 1036 and 1038 and a touch ofthe touch-sensitive area 1044) and sensor detection of user behavior maybe used to control movement of the movable support 1014.

In some embodiments, foam-in-bag systems are configured to clean the tipof dispensers that dispense foaming chemical precursors into bags. Thechemical precursors tend to foam at and near the tip of the dispensers.If left on the tip of the dispenser, the chemical precursors will tendto bond to cure and form an epoxy that is bonded to the dispenser. Suchbonding of the epoxy can prevent the chemical precursors from beingproperly dispensed or from being dispensed at all. In order to preventthe chemical precursors from curing at or near the dispenser and/orbonding to the dispenser, the foam-in-bag system dispenses a chemicalsolvent at the tip. The chemical solvent dissolves the chemicalprecursors and weakens any bond between the chemical precursors and thetip of the dispensers. When the next “shot” of chemical precursors isdispensed into a bag, the force of the newly-dispensed chemicalprecursors tends to cause any solvent-weakened chemical precursors onthe tip to dislodge and fall into the bag.

For the solvent to be effective, foam-in-bag machines typically dispensesolvent to the tip before a shot (sometimes called a “pre-shot” timeperiod), during the shot, and after the shot (sometimes called a“post-shot” time period). Applying solvent to the tip during thepre-shot period decreases the likelihood that the chemical precursorswill bond to the tip of the dispenser. Applying solvent to the tipduring the post-shot period decreases the likelihood that any chemicalprecursors remaining on the tip after the shot will cure on the tip ofthe dispenser. Foam-in-bag machines tend to start the flow of solventbefore a shot and end the flow of solvent after the shot so that solventflows during the pre-shot time period, during the shot, and during thepost-shot time period. In some embodiments, the solvent may includetripropylene glycol monomethyl ether, which is available under the nameDAWANOL from the Dow Chemical Company.

It would be advantageous to reduce the amount of chemical solvent usedto clean a dispenser. In the past, some foam-in-bag systems reduce theamount of solvent used by adding an agitant, such as compressed gas, tothe solvent. The addition of the agitant to the solvent can reduce theflow rate of solvent significantly. For example, when the agitant isadded to solvent, a solvent flow rate of 1 milliliter per second wouldbe as effective as a solvent flow rate of 6 milliliters per secondwithout the agitant. The reduced flow rate of the solvent due to theaddition of the agitant reduces cost and waste of the solvent. However,it also increases complexity of the foam-in-bag system because of needof the foam-in-bag system to have an agitation component that adds theagitant to the solvent.

Depicted in FIG. 13A is an embodiment of a system 1300 that dispensessolvent in a controlled manner to limit the amount of solvent used. Thesystem 1300 includes a source 1302 of a solvent 1304. In some examples,the source 1302 includes a drum, a barrel, a tank, a vat, a bottle, oranother container that is capable of holding the solvent 1304. In thedepicted embodiment, the source 1302 is in the form of a drum. Thesystem 1300 further includes a feed line 1306 that is configured totransport the solvent 1304 from a first end 1308 to a second end 1310 ofthe feed line 1306. In the depicted embodiment, the first end 1308 ofthe feed line 1306 is located inside the solvent 1304 in the source1302. The feed line 1306 is configured to convey solvent 1304 from thesource 1302 via the first end 1308 and to feed the solvent to the secondend 1310.

The system 1300 includes an inlet check value 1312 located near thefirst end 1308. The inlet check value 1312 is configured to preventbleeding of the solvent from the feed line 1306 back in to the source1304 and to prevent loss of prime and/or introduction of air into thefeed line 1306. The system 1300 includes a pump 1314 on the feed line1306 downstream of the inlet check valve 1312. The pump 1314 isconfigured to draw the solvent through the feed line 1306 from the firstend 1308 to the second end 1310. In some embodiments, the pump 1314includes one or more of a diaphragm pump, a peristaltic pump, a rotarypump, an impeller pump, or any other type of pump. In some embodiments,as is discussed below, the pump 1314 can be controlled to control a flowrate of the solvent 1304.

The system further includes a pressure transducer 1316 configured tomeasure pressure in the feed line 1306. In the depicted embodiment, thepressure transducer 1316 is located downstream of the pump 1316, wherethe pressure transducer 1316 is configured to detect pressure in thefeed line 1306 between the pump 1314 and the second end 1310. In someinstances, an increased pressure detected by the pressure transducer1316 indicates a clog or partial clog of the second end 1310 of the feedline 1306. The system 1300 further includes an outlet check valve 1318located near the second end 1310 of the feed line 1306. The outlet checkvalve 1318 is configured to deter unintended draining of the solvent1304 from the feed line 1306 out of the second end 1310.

In the depicted embodiment, the second end 1310 of the feed line 1306 islocated in a dispenser 1320 configured to dispense foaming chemicalprecursors. The dispenser 1320 includes a mixing chamber 1322 that is influid communication with each of a first precursor feed line 1324 and asecond precursor feed line 1326. Below the mixing chamber 1322, thedispenser 1320 has a tip 1328 for dispensing mixed foaming chemicalprecursors. The dispenser 1320 also has a valving rod 1330. When thevalving rod 1330 is in the open orientation shown in FIG. 13A, thevalving rod 1320 is retracted from the mixing chamber 1322, a firstchemical precursor 1334 is permitted to flow from the first precursorfeed line 1324 into the mixing chamber 1322, and a second chemicalprecursor 1336 is permitted to flow from the second precursor feed line1326 into the mixing chamber 1332. The first and second chemicalprecursors 1334 and 1336 form a mixture 1338 that is dispensed from thetip 1328 as it is begins to react to form foam. The valving rod 1330 canbe moved from the depicted open orientation to a closed orientationwhere the valving rod 1330 fills the mixing chamber to prevent flow ofthe first precursor feed line 1324 and the second precursor feed line1326 into the mixing chamber 1322. In some embodiments, when the valvingrod 1330 is in the closed orientation, the end of the valving rod 1330extends beyond the tip 1328 to prevent the curing of the first andsecond chemical precursors 1334 and 1336 over the tip 1328.

In the depicted embodiment, the second end 1310 of the feed line 1306 islocated in the dispenser 1320 in proximity to the tip 1328. When thepump 1314 operates, the solvent 1304 flows through the feed line 1306and the solvent 1304 flows out of the second end 1310 near the tip 1328.The system 1300 may be configured to dispense the solvent 1304 during apre-shot time period, during a shot, and during a post-shot time period.To accomplish this dispensing of the solvent 1304 in the depictedembodiment, the pump 1314 begins to operate before the valving rod 1330is retracted from the closed orientation, the pump 1314 continuesoperating while the valving rod 1330 is not in the closed orientation,and the pump 1314 continues operating after the valving rod 1330 isreturned to the closed orientation.

In some embodiments, the amount of solvent used by the system 1300 canbe reduced by controlling the pump 1314 to vary the flow rate of thesolvent 1304 during the pre-shot, shot, and post-shot time periods. Forexample, more of the solvent 1304 may be needed to clear residue ofchemical precursors during the post-shot time period than is neededduring the shot and/or during the pre-shot time period. In this example,the flow rate of the solvent 1304 can be lower during the pre-shot timeperiod and/or the shot than during the post-shot time period. Depictedin FIG. 13B is a chart showing an example of flow rates of the solvent1304 caused by controlling the pump 1314 over the course of a shot ofthe first and second chemical precursors.

In the chart in FIG. 13B, at time to, the pump 1314 is inactive and theflow rate of the solvent 1304 is Q₀ (e.g., no flow of the solvent 1304).A pre-shot time period is depicted between time t₁ and time t₂. In someembodiments, the time t₁ is a time determined as a specific amount oftime before the expected start of a shot at the time t₂. Near the timet₁, the flow rate of the solvent 1304 is increased to a flow rate Q₁ bycontrolling the pump 1314 to operate such that the flow rate of thesolvent 1304 reaches the flow rate Q₁. In some embodiments, the flowrate Q₁ is in a range between about 0.05 milliliters per second to about0.2 milliliters per second. In the depicted embodiment, the solvent 1304continues to flow at the flow rate Q, for the remainder of the pre-shottime period.

In the depicted embodiment, the shot begins at the time t₂ and continuesuntil a time t. In some embodiments, the time period of the shot may beany time that the dispenser permits foaming chemical precursors to bedispensed. In the example of the system 1300, the time period of theshot may be any time that the valving rod 1330 does not fully close offthe mixing chamber 1322. In the depicted embodiment, the solvent 1304continues to flow at the flow rate Q₁ for a majority of the shot. Theportion of the solvent 1304 dispensed during the shot encourages thefoaming chemical precursors to be dispensed from the dispenser 1320without foaming up inside the dispenser 1320 and/or clogging thedispenser 1320.

In the depicted embodiment, the flow rate of the solvent 1304 isincreased to a flow rate Q₂ before the time t so that the flow rate isat or near the flow rate Q₂ by the time the shot ends at the time t. Insome embodiments, the flow rate of the solvent 1304 is increased to theflow rate Q₂ by controlling the pump 1314 to operate such that the flowrate of the solvent 1304 reaches the flow rate Q₂. In some embodiments,the flow rate Q₂ is in a range between about 0.4 milliliters per secondto about 0.8 milliliters per second. This increased flow rate of thesolvent 1304 during the post-shot time period results in flushing outany residual foam near tip 1328 of the dispenser 1320 before the foamhas an opportunity to bond to any surface of the dispenser 1320 and/orprevent any foam residue near the tip 1328 of the dispenser 1320 fromhardening and/or crusting over.

In the depicted embodiment, the post-shot time period begins at the timet₃ and continues until a time t₄. In some embodiments, the time t₄ is atime determined as a specific amount of time after the end of the shotat the time t₃. In some embodiments, the amount of time of the post-shottime period (i.e., the amount of time between the time t₃ and the timet₄) is in a range from about 30 milliseconds to about 50 milliseconds.In the depicted embodiment, the solvent 1304 continues to flow at theflow rate Q₂ for nearly the remainder of the post-shot time period. Ator near end of the post-shot time period, the flow rate of the solvent1304 returns to the flow rate Q₀ (e.g., no flow of the solvent 1304).The flow rate of the solvent 1304 can remain at the flow rate Q₀ until anew pre-shot time period begins before a subsequent shot. The entiretime period shown in the chart in FIG. 13B can be repeated indefinitelyas each shot of the chemical precursors is dispensed into a differentbag. In some embodiments, a total amount of the solvent 1304 dispensedduring the pre-shot time period, during the dispensing of the shot, andduring the post-shot time period is less than or equal to about 2milliliters.

The chart shown in FIG. 13B is one example of a way in which the flowrate of the solvent 1304 can be controlled over the course of thepre-shot time period, the shot, and the post-shot time period. In thisembodiment, the flow rate of the solvent 1304 is controlled so that amaximum flow rate of the solvent 1304 during the pre-shot time period isless than a maximum flow rate of the solvent 1304 during the post-shottime period. It will be understood that, in other embodiments, thesolvent 1304 can be controlled in other ways so that the maximum flowrate of the solvent 1304 during the pre-shot time period is less than amaximum flow rate of the solvent 1304 during the post-shot time period.For example, in some embodiments, the flow rate of the solvent 1304 canbe increased from the flow rate Q₁ to the flow rate Q₂ earlier duringthe shot period; in some embodiments, the flow rate of the solvent 1304can be increased from the flow rate Q, to an intermediate flow rate ator near the time t₂ and then from the intermediate flow rate to the flowrate Q₂ at or near the time t₃; and, in other embodiments, the flow rateof the solvent 1304 can be controlled in any number of other ways.

FIG. 14 depicts an example embodiment of a system 1110 that may be usedto implement some or all of the embodiments described herein. In thedepicted embodiment, the system 1110 includes computing devices 1120 ₁,1120 ₂, 1120 ₃, and 1120 ₄ (collectively computing devices 1120). In thedepicted embodiment, the computing device 1120 ₁ is a tablet, thecomputing device 1120 ₂ is a mobile phone, the computing device 1120 ₃is a desktop computer, and the computing device 1120 ₄ is a laptopcomputer. In other embodiments, the computing devices 1120 include oneor more of a desktop computer, a mobile phone, a tablet, a phablet, anotebook computer, a laptop computer, a distributed system, a gamingconsole (e.g., Xbox, Play Station, Wii), a watch, a pair of glasses, akey fob, a radio frequency identification (RFID) tag, an ear piece, ascanner, a television, a dongle, a camera, a wristband, a wearable item,a kiosk, an input terminal, a server, a server network, a blade, agateway, a switch, a processing device, a processing entity, a set-topbox, a relay, a router, a network access point, a base station, anyother device configured to perform the functions, operations, and/orprocesses described herein, or any combination thereof.

The computing devices 1120 are communicatively coupled to each other viaone or more networks 1130 and 1132. Each of the networks 1130 and 1132may include one or more wired or wireless networks (e.g., a 3G network,the Internet, an internal network, a proprietary network, a securednetwork). The computing devices 1120 are capable of communicating witheach other and/or any other computing devices via one or more wired orwireless networks. While the particular embodiment of the system 1110 inFIG. 14 depicts that the computing devices 1120 communicatively coupledvia the network 1130 include four computing devices, any number ofcomputing devices may be communicatively coupled via the network 1130.

In the depicted embodiment, the computing device 1120 ₃ iscommunicatively coupled with a peripheral device 1140 via the network1132. In the depicted embodiment, the peripheral device 1140 is ascanner, such as a barcode scanner, an optical scanner, a computervision device, and the like. In some embodiments, the network 1132 is awired network (e.g., a direct wired connection between the peripheraldevice 1140 and the computing device 1120 ₃), a wireless network (e.g.,a Bluetooth connection or a WiFi connection), or a combination of wiredand wireless networks (e.g., a Bluetooth connection between theperipheral device 1140 and a cradle of the peripheral device 1140 and awired connection between the peripheral device 1140 and the computingdevice 1120 ₃). In some embodiments, the peripheral device 1140 isitself a computing device (sometimes called a “smart” device). In otherembodiments, the peripheral device 1140 is not a computing device(sometimes called a “dumb” device).

Depicted in FIG. 15 is a block diagram of an embodiment of a computingdevice 1200. Any of the computing devices 1120 and/or any othercomputing device described herein may include some or all of thecomponents and features of the computing device 1200. In someembodiments, the computing device 1200 is one or more of a desktopcomputer, a mobile phone, a tablet, a phablet, a notebook computer, alaptop computer, a distributed system, a gaming console (e.g., an Xbox,a Play Station, a Wii), a watch, a pair of glasses, a key fob, a radiofrequency identification (RFID) tag, an ear piece, a scanner, atelevision, a dongle, a camera, a wristband, a wearable item, a kiosk,an input terminal, a server, a server network, a blade, a gateway, aswitch, a processing device, a processing entity, a set-top box, arelay, a router, a network access point, a base station, any otherdevice configured to perform the functions, operations, and/or processesdescribed herein, or any combination thereof. Such functions,operations, and/or processes may include, for example, transmitting,receiving, operating on, processing, displaying, storing, determining,creating/generating, monitoring, evaluating, comparing, and/or similarterms used herein. In one embodiment, these functions, operations,and/or processes can be performed on data, content, information, and/orsimilar terms used herein.

In the depicted embodiment, the computing device 1200 includes aprocessing element 1205, memory 1210, a user interface 1215, and acommunications interface 1220. The processing element 1205, memory 1210,a user interface 1215, and a communications interface 1220 are capableof communicating via a communication bus 1225 by reading data fromand/or writing data to the communication bus 1225. The computing device1200 may include other components that are capable of communicating viathe communication bus 1225. In other embodiments, the computing devicedoes not include the communication bus 1225 and the components of thecomputing device 1200 are capable of communicating with each other insome other way.

The processing element 1205 (also referred to as one or more processors,processing circuitry, and/or similar terms used herein) is capable ofperforming operations on some external data source. For example, theprocessing element may perform operations on data in the memory 1210,data receives via the user interface 1215, and/or data received via thecommunications interface 1220. As will be understood, the processingelement 1205 may be embodied in a number of different ways. In someembodiments, the processing element 1205 includes one or more complexprogrammable logic devices (CPLDs), microprocessors, multi-coreprocessors, co processing entities, application-specific instruction-setprocessors (ASIPs), microcontrollers, controllers, integrated circuits,application specific integrated circuits (ASICs), field programmablegate arrays (FPGAs), programmable logic arrays (PLAs), hardwareaccelerators, any other circuitry, or any combination thereof. The termcircuitry may refer to an entirely hardware embodiment or a combinationof hardware and computer program products. In some embodiments, theprocessing element 1205 is configured for a particular use or configuredto execute instructions stored in volatile or nonvolatile media orotherwise accessible to the processing element 1205. As such, whetherconfigured by hardware or computer program products, or by a combinationthereof, the processing element 1205 may be capable of performing stepsor operations when configured accordingly.

The memory 1210 in the computing device 1200 is configured to storedata, computer-executable instructions, and/or any other information. Insome embodiments, the memory 1210 includes volatile memory (alsoreferred to as volatile storage, volatile media, volatile memorycircuitry, and the like), non-volatile memory (also referred to asnon-volatile storage, non-volatile media, non-volatile memory circuitry,and the like), or some combination thereof.

In some embodiments, volatile memory includes one or more of randomaccess memory (RAM), dynamic random access memory (DRAM), static randomaccess memory (SRAM), fast page mode dynamic random access memory (FPMDRAM), extended data-out dynamic random access memory (EDO DRAM),synchronous dynamic random access memory (SDRAM), double data ratesynchronous dynamic random access memory (DDR SDRAM), double data ratetype two synchronous dynamic random access memory (DDR2 SDRAM), doubledata rate type three synchronous dynamic random access memory (DDR3SDRAM), Rambus dynamic random access memory (RDRAM), Twin Transistor RAM(TTRAM), Thyristor RAM (T-RAM), Zero-capacitor (Z-RAM), Rambus in-linememory module (RIMM), dual in-line memory module (DIMM), single in-linememory module (SIMM), video random access memory (VRAM), cache memory(including various levels), flash memory, any other memory that requirespower to store information, or any combination thereof.

In some embodiments, non-volatile memory includes one or more of harddisks, floppy disks, flexible disks, solid-state storage (SSS) (e.g., asolid state drive (SSD)), solid state cards (SSC), solid state modules(SSM), enterprise flash drives, magnetic tapes, any other non-transitorymagnetic media, compact disc read only memory (CD ROM), compactdisc-rewritable (CD-RW), digital versatile disc (DVD), Blu-ray disc(BD), any other non-transitory optical media, read-only memory (ROM),programmable read-only memory (PROM), erasable programmable read-onlymemory (EPROM), electrically erasable programmable read-only memory(EEPROM), flash memory (e.g., Serial, NAND, NOR, and/or the like),multimedia memory cards (MMC), secure digital (SD) memory cards, MemorySticks, conductive-bridging random access memory (CBRAM), phase-changerandom access memory (PRAM), ferroelectric random-access memory (FeRAM),non-volatile random access memory (NVRAM), magneto-resistive randomaccess memory (MRAM), resistive random-access memory (RRAM), SiliconOxide-Nitride-Oxide-Silicon memory (SONOS), floating junction gaterandom access memory (FJG RAM), Millipede memory, racetrack memory, anyother memory that does not require power to store information, or anycombination thereof.

In some embodiments, memory 1210 is capable of storing one or more ofdatabases, database instances, database management systems, data,applications, programs, program modules, scripts, source code, objectcode, byte code, compiled code, interpreted code, machine code,executable instructions, or any other information. The term database,database instance, database management system, and/or similar terms usedherein may refer to a collection of records or data that is stored in acomputer-readable storage medium using one or more database models, suchas a hierarchical database model, network model, relational model,entity relationship model, object model, document model, semantic model,graph model, or any other model.

The user interface 1215 of the computing device 1200 is in communicationwith one or more input or output devices that are capable of receivinginputs into and/or outputting any outputs from the computing device1200. Embodiments of input devices include a keyboard, a mouse, atouchscreen display, a touch sensitive pad, a motion input device,movement input device, an audio input, a pointing device input, ajoystick input, a keypad input, peripheral device 1140, foot switch, andthe like. Embodiments of output devices include an audio output device,a video output, a display device, a motion output device, a movementoutput device, a printing device, and the like. In some embodiments, theuser interface 1215 includes hardware that is configured to communicatewith one or more input devices and/or output devices via wired and/orwireless connections.

The communications interface 1220 is capable of communicating withvarious computing devices and/or networks. In some embodiments, thecommunications interface 1220 is capable of communicating data, content,and/or any other information, that can be transmitted, received,operated on, processed, displayed, stored, and the like. Communicationvia the communications interface 1220 may be executed using a wired datatransmission protocol, such as fiber distributed data interface (FDDI),digital subscriber line (DSL), Ethernet, asynchronous transfer mode(ATM), frame relay, data over cable service interface specification(DOCSIS), or any other wired transmission protocol. Similarly,communication via the communications interface 1220 may be executedusing a wireless data transmission protocol, such as general packetradio service (GPRS), Universal Mobile Telecommunications System (UMTS),Code Division Multiple Access 2000 (CDMA2000), CDMA2000 1× (1×RTT),Wideband Code Division Multiple Access (WCDMA), Global System for MobileCommunications (GSM), Enhanced Data rates for GSM Evolution (EDGE), TimeDivision-Synchronous Code Division Multiple Access (TD-SCDMA), Long TermEvolution (LTE), Evolved Universal Terrestrial Radio Access Network(E-UTRAN), Evolution-Data Optimized (EVDO), High Speed Packet Access(HSPA), High-Speed Downlink Packet Access (HSDPA), IEEE 802.11 (WiFi),WiFi Direct, 802.16 (WiMAX), ultra wideband (UWB), infrared (IR)protocols, near field communication (NFC) protocols, Wibree, Bluetoothprotocols, wireless universal serial bus (USB) protocols, or any otherwireless protocol.

As will be appreciated by those skilled in the art, one or morecomponents of the computing device 1200 may be located remotely fromother components of the computing device 1200 components, such as in adistributed system. Furthermore, one or more of the components may becombined and additional components performing functions described hereinmay be included in the computing device 1200. Thus, the computing device1200 can be adapted to accommodate a variety of needs and circumstances.The depicted and described architectures and descriptions are providedfor exemplary purposes only and are not limiting to the variousembodiments described herein.

Embodiments described herein may be implemented in various ways,including as computer program products that comprise articles ofmanufacture. A computer program product may include a non-transitorycomputer-readable storage medium storing applications, programs, programmodules, scripts, source code, program code, object code, byte code,compiled code, interpreted code, machine code, executable instructions,and/or the like (also referred to herein as executable instructions,instructions for execution, computer program products, program code,and/or similar terms used herein interchangeably). Such non-transitorycomputer-readable storage media include all computer-readable media(including volatile and non-volatile media).

As should be appreciated, various embodiments of the embodimentsdescribed herein may also be implemented as methods, apparatus, systems,computing devices, and the like. As such, embodiments described hereinmay take the form of an apparatus, system, computing device, and thelike executing instructions stored on a computer readable storage mediumto perform certain steps or operations. Thus, embodiments describedherein may be implemented entirely in hardware, entirely in a computerprogram product, or in an embodiment that comprises combination ofcomputer program products and hardware performing certain steps oroperations.

Embodiments described herein may be made with reference to blockdiagrams and flowchart illustrations. Thus, it should be understood thatblocks of a block diagram and flowchart illustrations may be implementedin the form of a computer program product, in an entirely hardwareembodiment, in a combination of hardware and computer program products,or in apparatus, systems, computing devices, and the like carrying outinstructions, operations, or steps. Such instructions, operations, orsteps may be stored on a computer readable storage medium for executionbuy a processing element in a computing device. For example, retrieval,loading, and execution of code may be performed sequentially such thatone instruction is retrieved, loaded, and executed at a time. In someexemplary embodiments, retrieval, loading, and/or execution may beperformed in parallel such that multiple instructions are retrieved,loaded, and/or executed together. Thus, such embodiments can producespecifically configured machines performing the steps or operationsspecified in the block diagrams and flowchart illustrations.Accordingly, the block diagrams and flowchart illustrations supportvarious combinations of embodiments for performing the specifiedinstructions, operations, or steps.

For purposes of this disclosure, terminology such as “upper,” “lower,”“vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,”“front,” “rear,” and the like, should be construed as descriptive andnot limiting the scope of the claimed subject matter. Further, the useof “including,” “comprising,” or “having” and variations thereof hereinis meant to encompass the items listed thereafter and equivalentsthereof as well as additional items. Unless limited otherwise, the terms“connected,” “coupled,” and “mounted” and variations thereof herein areused broadly and encompass direct and indirect connections, couplings,and mountings. Unless stated otherwise, the terms “substantially,”“approximately,” and the like are used to mean within 5% of a targetvalue.

The principles, representative embodiments, and modes of operation ofthe present disclosure have been described in the foregoing description.However, aspects of the present disclosure which are intended to beprotected are not to be construed as limited to the particularembodiments disclosed. Further, the embodiments described herein are tobe regarded as illustrative rather than restrictive. It will beappreciated that variations and changes may be made by others, andequivalents employed, without departing from the spirit of the presentdisclosure. Accordingly, it is expressly intended that all suchvariations, changes, and equivalents fall within the spirit and scope ofthe present disclosure, as claimed.

What is claimed is:
 1. A system comprising: a dispenser configured todispense a first chemical precursor and a second chemical precursor; afirst feed line configured to permit flow of the first chemicalprecursor from a first source to the dispenser; a second feed lineconfigured to permit flow of the second chemical precursor from a secondsource to the dispenser; and a plurality of heating zones located alongthe first and second feed lines, wherein the plurality of heating zonesincludes a first heating zone located around a first portion of thefirst feed line and a second heating zone located around a first portionof the second feed line; wherein the first heating zone and the secondheating zone are independently controllable to independently controltemperature around the first portion of the first feed line that passesthrough the first heating zone and temperature around the first portionof the second feed line that passes through the second heating zone. 2.The system of claim 1, wherein the plurality of heating zones includes athird heating zone located around a second portion of the first feedline and a second portion of the second feed line, and wherein the thirdheating zone is controllable independently of the first and secondheating zones.
 3. The system of claim 2, wherein the second portion ofthe first feed line is downstream from the first portion of the firstfeed line, and wherein the second portion of the second feed line isdownstream from the first portion of the second feed line.
 4. The systemof claim 2, wherein the dispenser is located in the third heating zone.5. The system of claim 1, wherein each of the heating zones includes: aheating element configured to heat at least one of the first chemicalprecursor, the second chemical precursor, a block through which thefirst feed line passes, or a block through which the second feed linepasses.
 6. The system of claim 5, wherein each of the heating zonesfurther includes: a temperature sensor configured to measure atemperature of the at least one of the first chemical precursor, thesecond chemical precursor, the block through which the first feed linepasses, or the block through which the second feed line passes.
 7. Thesystem of claim 6, wherein each of the heating zones further includes: acontroller configured to control the heating element based onindications of the measured temperature generated by the temperaturesensor.
 8. The system of claim 7, wherein the controller is configuredto control the heating element by alternating, based on the indicationsof the measured temperature generated by the temperature sensor, betweencausing the heating element to be powered and causing the heatingelement to be unpowered.
 9. The system of claim 1, further comprising: afirst dispenser manifold comprising a first input block, wherein thefirst input block is the first heating zone and the first portion of thefirst feed line passes through the first input block; and a seconddispenser manifold comprising a second input block, wherein the secondinput block is the second heating zone and the first portion of thesecond feed line passes through the second input block.
 10. The systemof claim 9, wherein: the first dispenser manifold further comprises afirst output block, wherein the first output block is in a third heatingzone through which a second portion of the first feed line passes; andthe second dispenser manifold further comprises a second output block,wherein the second output block is in a fourth heating zone throughwhich a second portion of the second feed line passes.
 11. The system ofclaim 10, wherein: the first input block includes a first heatingelement configured to heat the first input block, a first temperaturesensor configured to measure a temperature of the first input block, anda first controller configured to control operation of the first heatingelement based on the measured temperature from the first temperaturesensor; the second input block includes a second heating elementconfigured to heat the second input block, a second temperature sensorconfigured to measure a temperature of the second input block, and asecond controller configured to control operation of the second heatingelement based on the measured temperature from the second temperaturesensor; the first output block includes a third heating elementconfigured to heat the first output block, a third temperature sensorconfigured to measure a temperature of the first output block, and athird controller configured to control operation of the third heatingelement based on the measured temperature from the third temperaturesensor; and the second output block includes a fourth heating elementconfigured to heat the second output block, a fourth temperature sensorconfigured to measure a temperature of the second output block, and afourth controller configured to control operation of the fourth heatingelement based on the measured temperature from the fourth temperaturesensor.
 12. The system of claim 11, further comprising: a mixingcartridge manifold in the dispenser, wherein a fifth heating zone is inthe mixing cartridge manifold, and wherein a third portion of the firstfeed line and a third portion of the second input line pass through thefifth heating zone in the mixing cartridge manifold.
 13. The system ofclaim 12, wherein: the dispenser includes a fifth heating elementconfigured to heat the mixing cartridge manifold, a fifth temperaturesensor configured to measure a temperature of the mixing cartridgemanifold, and a fifth controller configured to control operation of thefifth heating element based on the measured temperature from the fifthtemperature sensor.
 14. The system of claim 13, further comprising: afirst hose coupled to a first input of the first dispenser manifold,wherein a fourth portion of the first feed line passes through the firsthose, wherein the first hose includes a sixth heating element configuredto heat the first chemical precursor passing through the fourth portionof the first feed line; and a second hose coupled to a second input ofthe second dispenser manifold, wherein a fourth portion of the secondfeed line passes through the second hose, wherein the second hoseincludes a seventh heating element configured to heat the secondchemical precursor passing through the fourth portion of the second feedline.
 15. The system of claim 14, further comprising: a sixthtemperature sensor configured to measure a temperature of the firstchemical precursor passing through the fourth portion of the first feedline; and a sixth controller configured to control operation of thesixth heating element based on the measured temperature from the sixthtemperature sensor.
 16. The system of claim 10, wherein the first outputblock further includes a secondary line configure to permit flow of acleaning solution to the dispenser, wherein the secondary line passesthrough the third heating zone.
 17. A method comprising: dispensing, bya dispenser, a first chemical precursor and a second chemical precursor;permitting flow of the first chemical precursor from a first source,through a first feed line, and to the dispenser; permitting flow of thesecond chemical precursor from a second source, through a second feedline, and to the dispenser; independently controlling a first heatingzone and a second heating zone of a plurality of heating zones locatedalong the first and second feed lines, wherein the first heating zone islocated around a first portion of the first feed line, wherein thesecond heating zone is located around a first portion of the second feedline, and wherein the independently controlling comprises independentlycontrolling temperature around the first portion of the first feed linethat passes through the first heating zone and temperature around thefirst portion of the second feed line that passes through the secondheating zone.
 18. The method of claim 17, wherein the plurality ofheating zones includes a third heating zone located around a secondportion of the first feed line and a second portion of the second feedline, and wherein the method further comprises the third heating zoneindependently of the first and second heating zones.
 19. The method ofclaim 18, wherein the second portion of the first feed line isdownstream from the first portion of the first feed line, and whereinthe second portion of the second feed line is downstream from the firstportion of the second feed line, wherein the dispenser is located in thethird heating zone.
 20. The method of claim 17, wherein each of theheating zones includes a heating element configured to heat at least oneof the first chemical precursor, the second chemical precursor, a blockthrough which the first feed line passes, or a block through which thesecond feed line passes.